Graco 3A0870G, ProMix 2KE Plural Component Proportioner , Repair/Parts Owner's Manual
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Repair/Parts
ProMix
®
2KE
Plural Component Proportioner
3A0870G
EN
Self-contained, electronic plural component paint proportioner. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
See pages 3 and 4 for model information, including maximum working pressure and approvals.
For patent information, see www.graco.com/patents
Pump System Meter System ti15696a ti15698a
2
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Non-Hazardous Location Models . . . . . . . . . . . . . . 3
Hazardous Location Models . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Important Two-Component Material Information . 8
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 8
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 8
Keep Components A and B Separate . . . . . . . . . 8
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 9
Pump Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Meter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump Systems . . . . . . . . . . . . . . . . . . . . . . . . . 10
Meter Systems . . . . . . . . . . . . . . . . . . . . . . . . . 11
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance Recommendations. . . . . . . . . . . . . . 12
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . 13
Replace the Air Filter Element . . . . . . . . . . . . . 13
Replace Solenoids . . . . . . . . . . . . . . . . . . . . . . 14
Replace the Power Supply . . . . . . . . . . . . . . . . 15
Replace Alternator Regulator . . . . . . . . . . . . . . 18
Replace Advanced Fluid Control
Module (AFCM) . . . . . . . . . . . . . . . . . . . . . 18
Replace Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 19
Replace Display Module . . . . . . . . . . . . . . . . . . 19
Replace USB Module . . . . . . . . . . . . . . . . . . . . 20
Update Software . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump System Air Controls . . . . . . . . . . . . . . . . 22
Meter System Air Controls . . . . . . . . . . . . . . . . 23
Fluid Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Repair Flow Meters . . . . . . . . . . . . . . . . . . . . . . 27
Repair Mix Manifold . . . . . . . . . . . . . . . . . . . . . 27
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . 29
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pump-Based Proportioners, Models
24F088-24F115 . . . . . . . . . . . . . . . . . . . . . 30
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Models 24F088-24F115 . . . . . . . . . . . . . . . 35
Models 24F088-24F115 . . . . . . . . . . . . . . . 36
Meter-Based Proportioners, Models
24F080-24F087 . . . . . . . . . . . . . . . . . . . . . 38
Models 24F080-24F087 . . . . . . . . . . . . . . . 41
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
USB Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electric Power Assembly . . . . . . . . . . . . . . . . . . 45
Alternator Power Assembly . . . . . . . . . . . . . . . . 46
Alternator Module 255728 . . . . . . . . . . . . . . . . . 47
Sequential Dosing Mix Manifold 262398 . . . . . . 48
Dynamic Dosing Mix Manifold 262399 . . . . . . . 48
1-Color/1 Solvent Valve Stack . . . . . . . . . . . . . . 49
3-Color/1 Solvent Valve Stack . . . . . . . . . . . . . . 49
Meter Stand Kit 24G611 . . . . . . . . . . . . . . . 50
Air Flow Switch Kit 15T632 . . . . . . . . . . . . . . . . 50
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 60
3A0870G
Related Manuals
Related Manuals
Manual
3A0868
3A0869
313599
308778
312781
312782
312784
312792
312793
312796
Description
ProMix 2KE, Pump-Based, Operation
ProMix 2KE, Meter-Based, Operation
Coriolis Meter
G3000 Flow Meter
Fluid Mix Manifold
Dosing Valve
Gun Flush Box Kit 15V826
Merkur Displacement Pump
Merkur Bellows Displacement Pump
NXT Air Motor
Manual
406714
406823
3A1244
3A1323
3A1324
3A1325
3A1332
3A1333
313542
Description
Rebuild Kit for High Pressure
Dispense Valve
Dispense Valve Seat Kit
Graco Control Architecture
Module Programming
16G353 Alternator Conversion Kit
16G351 Electric Power Conversion Kit
ProMix 2KE Stand Kits
24H255 3-Color Valve Stack Kit
24H253 USB Module Kit
Beacon Tower
Non-Hazardous Location Models
*
Approved for Non-Hazardous Location
Maximum Working
Pressure psi (MPa, bar)
USB
Module Approvals* Part No. Series Description
24F088
24F089
24F090
24F091
24F092
24F093
24F094
24F095
24F096
24F097
24F098
24F099
24F100
24F101
A
A
A
A
A
A
A
A
A
A
A
A
A
A
Meter Systems
24F080 A
24F081 A
24F082 A
24F083 A
Pump Systems
3:1, Merkur, A and B
23:1, Merkur, A and B
30:1, Merkur, A and B
45:1, Merkur, A and B
300 (2.1, 21)
2300 (15.8, 158)
3000 (20.7, 207)
4500 (31.0, 310)
3:1, Merkur A, Merkur Bellows B 300 (2.1, 21)
23:1, Merkur A, Merkur Bellows B 2300 (15.8, 158)
35:1, Merkur A, Merkur Bellows B 3500 (24.1, 241)
3:1, Merkur, A and B
23:1, Merkur, A and B
30:1, Merkur, A and B
45:1, Merkur, A and B
300 (2.1, 21)
2300 (15.8, 158)
3000 (20.7, 207)
4500 (31.0, 310)
3:1, Merkur A, Merkur Bellows B 300 (2.1, 21)
23:1, Merkur A, Merkur Bellows B 2300 (15.8, 158)
35:1, Merkur A, Merkur Bellows B 3500 (24.1, 241)
G3000, 1 color/1 catalyst
G3000, 3 colors/1 catalyst
G3000, 1 color/1 catalyst
G3000, 3 colors/1 catalyst
3000 (27.58, 275.8)
3000 (27.58, 275.8)
3000 (27.58, 275.8)
3000 (27.58, 275.8)
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
# 53
* ProMix 2KE non-hazardous location equipment manufactured in the United States, with serial number beginning with A or 01, has FM and CE approvals. Equipment manufactured in Belgium, with serial number beginning with
M or 38, has CE approval.
3A0870G 3
4
Hazardous Location Models
Hazardous Location Models
ProMix 2KE systems are not approved for use in hazardous locations unless the base model, all accessories, all kits, and all wiring meet local, state, and national codes.
Approved for Hazardous Location
Class 1, Div 1, Group D (North America); Class 1, Zones 1 and 2 (Europe)
Part No. Series Description
24F102
24F103
24F104
24F105
24F106
24F107
24F108
24F109
24F110
24F111
24F112
24F113
24F114
A
A
24F115 A
Meter Systems
A
A
A
A
24F084
24F085
24F086
24F087
A
A
A
A
A
A
A
A
A
A
A
G3000, 1 color/1 catalyst
G3000, 3 colors/1 catalyst
G3000, 1 color/1 catalyst
G3000, 3 colors/1 catalyst
Maximum Working
Pressure psi (MPa, bar)
USB
Module Approvals*
Pump Systems
3:1, Merkur, A and B
23:1, Merkur, A and B
30:1, Merkur, A and B
300 (2.1, 21)
2300 (15.8, 158)
3000 (20.7, 207)
45:1, Merkur, A and B 4500 (31.0, 310)
3:1, Merkur A, Merkur Bellows B 300 (2.1, 21)
23:1, Merkur A, Merkur Bellows B 2300 (15.8, 158)
35:1, Merkur A, Merkur Bellows B 3500 (24.1, 241)
3:1, Merkur, A and B
23:1, Merkur, A and B
30:1, Merkur, A and B
45:1, Merkur, A and B
300 (2.1, 21)
2300 (15.8, 158)
3000 (20.7, 207)
4500 (31.0, 310)
3:1, Merkur A, Merkur Bellows B 300 (2.1, 21)
23:1, Merkur A, Merkur Bellows B 2300 (15.8, 158)
35:1, Merkur A, Merkur Bellows B 3500 (24.1, 241)
3000 (27.58, 275.8)
3000 (27.58, 275.8)
✔
✔
✔
✔
✔
✔
✔
3000 (27.58, 275.8)
✔
3000 (27.58, 275.8)
✔
II 2 G
Ex ia px IIA T3 Ta = 0°C to 54°C
FM10 ATEX 0025 X
# 53
Intrinsically safe and purged equipment for
Class I, Division 1, Group D, T3
Ta = 0°C to 54°C
0359
See Special Conditions for Safe
Use in
* ProMix 2KE hazardous location equipment manufactured in the United States, with serial number beginning with
A or 01, has ATEX, FM, and CE approvals, as noted. Equipment manufactured in Belgium, with serial number beginning with M or 38, has ATEX and CE approvals, as noted.
3A0870G
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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, 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.
• If there is static sparking or you feel a shock, stop operation immediately.
Do not use equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SPECIAL CONDITIONS FOR SAFE USE
• To prevent the risk of electrostatic sparking, the equipment’s non-metallic parts should be cleaned only with a damp cloth.
• Pump Systems: The aluminum adapter plate may spark upon impact or contact with moving parts, which may cause fire or explosion. Take precautions to avoid such impact or contact.
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 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.
3A0870G 5
6
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.
• Only models with model numbers 24F084-24F087 and 24F102-24F115, utilizing the air-driven alternator, are approved for installation in a Hazardous (explosive atmosphere) Location. See
Hazardous Location Models , page 4.
• 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, NFPA 33, NEC 500 and 516, and
OSHA 1910.107.
• 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.
• The equipment is intrinsically safe when no external electrical components are connected to it.
• Do not connect, download, or remove USB device unless unit is removed from the hazardous
(explosive atmosphere) location.
SKIN INJECTION HAZARD
High-pressure fluid from gun, 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 spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying 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.
3A0870G
3A0870G
Warnings
WARNING
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.
• 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.
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 HAZARD
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.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This 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.
7
8
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.
Read 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.
Material Self-ignition
Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.
Keep Components A and B
Separate
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component coatings. ISO will react with moisture (such as humidity) to form 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. If used, this partially cured ISO will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.
To prevent exposing ISO to moisture:
• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.
• Never use solvent on one side if it has been contaminated from the other side.
• Always lubricate threaded parts with ISO pump oil or grease when reassembling.
Changing Materials
• 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.
Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (resin) and component B (isocyanate) parts.
3A0870G
Pressure Relief Procedure
Pressure Relief Procedure
Meter Systems
To reduce the risk of skin injection, relieve pressure when you stop spraying, before changing spray tips, and before cleaning, checking, or servicing equipment.
NOTE: The following procedure relieves all fluid and air pressure in the ProMix 2KE system.
Pump Systems
1.
Press on Run Mix Spray (Screen 2) or from any screen to put the system in Standby.
2.
Follow procedure for Purging Fluid Supply System , page 10, if desired or necessary.
3.
Shut off air supply to A and B pumps and solvent supply pumps.
4.
With the gun triggered, push the manual override on the A and B dose and solvent valve solenoids to
relieve pressure. See F IG . 1, page 12. Verify that
fluid pressure is reduced to 0.
5.
Reinstall the Control Box cover.
1.
Press on Run Mix Spray (Screen 2) or from any screen to put the system in Standby.
2.
Shut off the A1 (A2 and A3, if using multiple colors) and B fluid supply pumps/pressure pots.
3.
Remove the Control Box cover.
4.
With the gun triggered, push the manual override on the A1 (A2, A3), and B dose valve solenoids to
relieve pressure. See F IG . 1, page 12.
5.
Follow
6.
Shut off the fluid supply to solvent valves A and B.
7.
With the gun triggered, push the manual override on the A and B solvent valve solenoids to relieve sol-
vent pressure. See F IG . 1. Verify that solvent pres-
sure is reduced to 0.
8.
Reinstall the Control Box cover.
3A0870G 9
Purging
Purging
Pump Systems
There are 2 pump purging procedures in this manual:
•
•
Use the criteria listed for each procedure to determine which procedure to use.
Purging Mixed Material
There are times when you only want to purge the fluid manifold, such as:
• end of potlife
• breaks in spraying that exceed the potlife
• overnight shutdown
• before servicing the fluid manifold assembly, hose or gun.
1.
Press on Run Mix Spray (Screen 2) or from any screen to put the system in Standby.
2.
Trigger the gun to relieve pressure.
3.
If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.
4.
If using an electrostatic gun shut off the electrostatics before flushing the gun.
5.
Set the solvent supply pressure regulator at a pressure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury. Generally, a setting of 100 psi (0.7 MPa, 7 bar) is sufficient.
6.
If using a gun flush box, place the gun into the box and close the lid. Press on Run Mix Spray
(Screen 2). The purge sequence automatically starts.
If the gun flush box is not used, trigger the gun into a grounded metal pail until the purge sequence is complete.
When done purging, the system automatically switches to Standby mode.
7.
If the system is not completely clean, repeat step 6.
NOTE: If necessary, adjust purge sequence so only one cycle is required.
8.
Trigger the gun to relieve pressure. Engage trigger lock.
9.
If spray tip was removed, reinstall it.
10. Adjust the solvent supply regulator back to its normal operating pressure.
NOTE: If your system uses 2 guns, you must trigger both guns simultaneously during a purge to purge both guns and lines. Verify that clean solvent flows from each gun. If not, repeat purge or clear clog/blockage in system.
Purging Fluid Supply System
Follow this procedure before:
• the first time material is loaded into equipment
• servicing
• shutting down equipment for an extended period of time
• putting equipment into storage
1.
Press on Run Mix Spray (Screen 2) or from any screen to put the system in Standby.
2.
Trigger the gun to relieve pressure.
3.
If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.
4.
If using an electrostatic gun, shut off the electrostatics before flushing the gun.
10 3A0870G
Purging
5.
Disconnect the component A and B fluid supplies at the pump inlets, and connect solvent supply lines.
6.
Adjust the solvent fluid supply pressure. Use the lowest possible pressure to avoid splashing.
7.
Remove the Control Box cover to access the sole-
8.
Purge as follows:
•
Press the manual override on the Dose Valve A solenoid valve and trigger the gun into a grounded metal pail.
Purge component B side. Press the manual override on the Dose Valve B solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from the gun.
Repeat to thoroughly clean the mix manifold.
9.
Reinstall the Control Box cover.
10. Shut off the solvent fluid supply.
11. Disconnect the solvent supply lines and reconnect the component A and B fluid supplies.
NOTE: If your system uses 2 guns, you must trigger both guns simultaneously during a purge to purge both guns and lines. Verify that clean solvent flows from each gun. If not, repeat purge or clear clog/blockage in system.
NOTE: The system remains full of solvent.
Meter Systems
Purge the system:
• at the end of potlife
• breaks in spraying that exceed the potlife
• overnight shutdown or end of shift
• the first time material is loaded into equipment
• servicing
• shutting down equipment for an extended period of time
1.
Press on Run Mix Spray (Screen 2) or from any screen to put the system in Standby.
2.
Trigger the gun to relieve pressure.
3.
If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.
4.
If using an electrostatic gun shut off the electrostatics before flushing the gun.
5.
Set the solvent supply pressure regulator at a pressure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury. Generally, a setting of 100 psi (0.7 MPa, 7 bar) is sufficient.
6.
If using a gun flush box, place the gun into the box and close the lid.
7.
Press on Run Mix Spray (Screen 2). The purge sequence automatically starts.
If the gun flush box is not used, trigger the gun into a grounded metal pail until the system returns to
Standby mode.
8.
If the system is not completely clean, repeat step 6.
NOTE: If necessary, adjust purge sequence so only one cycle is required.
9.
Trigger the gun to relieve pressure. Engage trigger lock.
10. If spray tip was removed, reinstall it.
11. Adjust the solvent supply regulator back to its normal operating pressure.
NOTE: The system remains full of solvent.
NOTE: If your system uses 2 guns, you must trigger both guns simultaneously during a purge to purge both guns and lines. Verify that clean solvent flows from each gun. If not, repeat purge or clear clog/blockage in system.
3A0870G 11
Purging
Manual Overrides
Solvent Valve A
Solenoid
Dose Valve A1
Solenoid
Solvent Valve B
Solenoid
Dose Valve B
Solenoid
F IG . 1. Solenoid Valves in Control Box
Dose Valve A3
Solenoid Location
Gun Flush Box
Solenoid Location
Dose Valve A2
Solenoid Location ti15730a
Shutdown
1.
Follow Purging procedure for your system, page 10
2.
Close main air shutoff valve on air supply line and on ProMix 2KE.
3.
Non-IS Systems: Shut off ProMix 2KE power
(0 position). NOTE: Meter-based systems will restart in Recipe 0.
Maintenance
Recommendations
The following table shows starting maintenance recommendations. Maintenance needs will vary based on individual applications and material differences.
Component
Solvent Valves
Fluid Filter
Air Filter
Pumps
Dose Valves
Meters
Recommended Maintenance
Frequency
1,000,000 cycles daily monthly
250,000 cycles
1,000,000 cycles
5,000 gallons
12 3A0870G
Service
Service
Before Servicing
• To avoid electric shock, turn off power before servicing.
• Servicing the Control Box exposes you to high voltage. Shut off power at main circuit breaker before opening enclosure.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
• Do not substitute system components as this may impair intrinsic safety.
1.
Follow Pressure Relief Procedure , page 9, if ser-
vice time may exceed pot life time, before servicing fluid components, and before transporting equipment to a service area.
2.
Close air shutoff valves.
3.
Non-IS Systems: Shut off power (0 position).
4.
If servicing Control Box, also shut off power at main circuit breaker.
Replace the Air Filter Element
4.
Remove and replace element (206a, 209a).
5.
Screw filter bowl (B) on securely. Install cover (A).
Pump
System
209
Meter
System
209
206 ti15708a ti16437a
Removing a pressurized air filter bowl could cause serious injury. Depressurize air line before servicing.
Pump systems have two air filters: the 5 micron air manifold filter (209) and the 40 micron pump air filter (206).
Meter systems have only the 5 micron filter (209). Check filters daily and replace element(s) as needed. Order
15D909 (5 micron) or 15D890 (40 micron).
1.
Close main air shutoff valve on air supply line and on system. Depressurize air line.
2.
Remove the filter cover (A).
3.
Unscrew the filter bowl (B).
ti12691a
F IG . 2. Replace Air Filter Element(s)
206a, 209a
B
A
3A0870G 13
Service
Replace Solenoids
The system has a minimum of 4 solenoids. If you have a
3-color system or a gun flush box, you have additional
(optional) solenoids for each.
To replace a single solenoid:
1.
Follow
Before Servicing , page 13. Disconnect
main power.
2.
Open Control Box.
3.
Disconnect 2 solenoid wires (N) from harness (320).
4.
Unscrew 2 screws (P) and remove solenoid (306).
5.
Install new solenoid (306).
6.
Connect 2 wires (N) to harness (320). Solenoid wires are polarized (red+, black-). Refer to System
Electrical Schematics, pages 54-57.
7.
Replace Control Box cover.
320 320
To replace the solenoid module:
1.
Follow Before Servicing , page 13. Disconnect
main power.
2.
Open Control Box.
3.
Disconnect all solenoid wires (N) from harnesses
(320).
NOTE: If you have an intrinsically safe model, you will need to remove the alternator air regulator from the
solenoid module. See page 18 for removal instructions.
4.
Remove two screws (305).
5.
Remove and replace solenoid module.
6.
Connect all wires (N) to harnesses (320). Solenoid wires are polarized (red+, black-). Refer to System
Electrical Schematics, pages 54-57.
7.
Replace Control Box cover.
305
N
P ti16450a
F IG . 4. Replace Solenoid Module
306
F IG . 3. Replace a Single Solenoid ti16646a
14 3A0870G
Service
Replace the Power Supply
All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations.
Wall Power Supply and Filter
1.
Follow Before Servicing , page 13. Disconnect
main power.
2.
Open Control Box.
3.
Disconnect the three input wires from the line filter
(403).
10. Connect the power supply wire harness (411/PS) to the switch (402), as shown. See also Electrical
Schematic. Connect the PS ground wire to the ground terminal (T) of the advanced fluid control module.
. 5. Connect wire harness (411) to the line
filter (403) and terminal block (404) as shown. See also Electrical Schematic.
12. Connect CAN cable (401a) to the advanced fluid control module.
Connect cable
(401a) here.
403
411
Line 404 ti16602a
F IG . 6. Reconnect CAN cable.
Ground
Neutral ti16391a
F IG . 5. Terminal Block Electrical Connections
4.
See F IG . 8. Disconnect the power supply CAN cable
(401a) from the advanced fluid control module
(302).
5.
Disconnect line filter wires and power supply wires from the power switch (402).
6.
Disconnect the power supply ground wire,
PS(GND), from the advanced fluid control module ground terminal (T).
7.
Remove four screws (405) and remove power supply (401). If replacing filter, remove two screws (407) and the filter (403).
8.
Install the new power supply (401) and line filter
(403), using supplied screws (405, 407), as shown.
9.
See F IG . 8. Connect wire harness (410/LF) to the line filter (403) and to the power switch (402), as shown. See also Electrical schematic.
TERMINAL
BLOCK
L N GRND
L GRND N
LINE POWER
FILTER
L N
2A
2
SWITCH
ROCKER
1A
1
F IG . 7. Electrical Schematic
POWER
SUPPLY
3A0870G 15
Service
2: PS(L)
1A: LF(N)
302
T
PS(GND)
405
401
PS(L)
PS(N)
407
406
F IG . 8. Replace Wall Power Supply
402
1: PS(N)
1A: LF(N)
LF(L)
LF(N)
401a ti16454a
403
16 3A0870G
Service
Alternator Power Supply and Turbine
1.
Follow Before Servicing , page 13. Disconnect
main air.
2.
Open Control Box.
3.
. 9. Disconnect output power cable connec-
tions from alternator module (501). Disconnect ground lead (G) from control box ground terminal
(T).
4.
Disconnect the power supply cables from the
Advanced Fluid Control Module, the USB Module, and the Display Module.
Air regulator line
5.
Disconnect air regulator line and exhaust air line from alternator module.
6.
Remove four screws (509) from mounting to remove alternator from control box.
7.
Remove seven screws (501h) to separate alternator housings.
8.
Replace turbine (501d) if necessary. Lightly lubricate turbine o-ring to ease alternator housing reassembly.
9.
Follow steps in reverse order to reassemble alternator regulator assembly and to reconnect power
T
Cable connectors
Supply line disconnect
501
F IG . 9. Remove Alternator Module (and Turbine)
3A0870G ti16456a
509
501h
G
501d ti16455a
Exhaust air line disconnect
17
Service
Replace Alternator Regulator
1.
Follow
Before Servicing , page 13. Disconnect
main air.
2.
Open Control Box.
3.
Disconnect supply air line from regulator assembly
(505).
4.
Loosen air regulator swivel fittings (506) and remove from solenoid module.
5.
Repair or replace alternator regulator parts as nec-
essary. See Alternator Power Assembly , page 46,
for repair parts. Replace air regulator swivel fitting
(506).
6.
Reconnect air line. Set regulator air pressure to
18 psi (0.12 MPa, 1.2 bar).
NOTICE
To avoid damage to the alternator, do not set the regulator air pressure higher than 18 psi
(0.12 MPa, 1.2 bar).
7.
Close Control Box and restore power.
Air regulator line
Replace Advanced Fluid Control
Module (AFCM)
1.
Follow Before Servicing , page 13. Disconnect
main power.
2.
Open Control Box.
3.
Remove all cables from AFCM (302). Take note of cable locations.
4.
Disconnect ground wire from ground screw (GS).
5.
Loosen four mounting screws (303).
6.
Slide AFCM up and out of keyhole slots.
7.
Follow steps in reverse order to install a new AFCM.
See electrical schematic for cable connection information.
8.
Follow instructions in Manual 3A1244 to update the software on the new AFCM.
9.
Close Control Box and restore power.
303 302
506
Solenoid
Module
505
F IG . 10. Replace Alternator Regulator ti16456a
F IG . 11. Replace AFCM
GS
18 ti16452a
3A0870G
Service
Replace Alarm
1.
Follow Before Servicing , page 13. Disconnect
main power.
2.
Open Control Box.
3.
Disconnect alarm wires from alarm (311).
4.
Unscrew alarm jam/mounting nut to remove alarm.
5.
Assemble new alarm. Reconnect alarm wires.
6.
Close Control Box and restore power.
Replace Display Module
1.
Follow
2.
The Display Module (63) snaps tightly into the mounting bracket (49). To remove it, lift up on the front of the bracket and, at the same time, pull the
Display Module out.
3.
Disconnect the CAN cable (64).
4.
Replace with a new Display Module.
5.
Reconnect the CAN cable (64) as shown.
6.
Follow instructions in Manual 3A1244 to update the software on the new Display Module.
Lift here.
311
F
IG
. 12. Replace Alarm
3A0870G ti16453a 64 ti16672a
J6
Connect cable (64) here
(either port).
F IG . 13. Replace Display Module ti16604a
19
Service
Replace USB Module
USB Module
1.
Follow
Before Servicing , page 13. Disconnect
main power.
2.
Open Control Box.
3.
Non-IS Systems: Disconnect Display Module CAN cable, Advanced Fluid Control Module CAN cable and USB cable from the USB module (340).
IS Systems: Disconnect Alternator CAN cable and
USB cable from the USB module (340).
4.
Remove ground screw (343) from top of Control Box for USB module and bracket.
5.
Remove four mounting screws (341) from USB module and remove module.
6.
Follow steps in reverse order to install a new USB module.
Non-IS Systems Cable Connections:
• CAN cable from J6 (either port) on the Display
Module to P3 on the USB Module.
• CAN cable from J8 on the Advanced Fluid Control Module to P4 on the USB Module
• USB cable (345) from the port on the Control
Box to the port on the USB Module.
IS Systems Cable Connections:
• CAN cable from J2 on the Alternator Module to
P3 on the USB Module.
• USB cable (345) from the port on the Control
Box to the port on the USB Module.
7.
Follow instructions in Manual 3A1244 to update the software on the new USB Module.
8.
Close Control Box and restore power.
P4
P3
Display Module ti16604a
J6
F IG . 14. USB Non-IS Cable Connections
P3
USB Module ti16580a
J2 ti16580a
J8
F IG . 15. USB IS Cable Connections.
Advanced
Fluid Control
Module ti16579a
Alternator Module ti15710a
To help prevent fire and explosion, do not connect, download, or remove the USB flash drive unless the unit is removed from the hazardous (explosive atmosphere) location. Never leave the USB flash drive in the USB port.
Update Software
Order Software Token Kit 16D922 to update software.
Manuals 3A1244 and 406905 will accompany all software updates. Follow all instructions and warnings in these manuals to update your Display Module,
Advanced Fluid Control Module, and USB Module (if used).
20 3A0870G
348
340
F IG . 16. Replace USB Module
345
349
342
343
342
341 (X 4)
Service ti16451a
3A0870G 21
Service
Pump System Air Controls
Remove Air Control Assembly
1.
Follow
2.
. 17. Disconnect pump air lines, main air
line, and solenoid air line.
NOTE: You may prefer to remove the A side air motor air line after you remove the assembly from the frame.
3.
Loosen four screws (8) from sides of frame. Slide the assembly up and out to remove.
4.
Follow steps in reverse order to reinstall air control assembly after repair.
Solenoid air
Main air ti16457a
8
Pump air
Replace Pressure Gauge(s)
1.
See Remove Air Control Assembly , page 22.
See F IG . 18, page 23, for a full diagram of the pump air
controls.
2.
Disconnect air lines to gauges (203).
3.
Remove mounting screws (203a).
4.
Remove fittings (211) and gauges (203). Replace as needed.
5.
Follow steps in reverse order to reassemble.
Replace Air Regulators
1.
See Remove Air Control Assembly , page 22.
2.
See F IG . 18, page 23. Remove regulator nut (205)
and disconnect air lines running to regulator (204).
3.
Remove regulator assembly and replace with new.
See Air Controls, Pump-Based Models
4.
Follow steps in reverse order to reassemble.
Replace Manifold/Ball Valve/Safety Valve
1.
See Remove Air Control Assembly , page 22.
2.
See F IG . 18, page 23. Remove nut (202b) and han-
dle (202a) from front of air control plate.
3.
Remove four screws (222) from front of air control plate.
4.
Disconnect all air lines.
5.
Disconnect fittings (207, 212, 214, 215). Replace as necessary.
6.
Disconnect ball valve (202) and safety valve (219).
Replace parts as necessary, including manifold.
See Air Controls, Pump-Based Models
7.
Follow steps in reverse order to reassemble.
ti15708a
F IG . 17. Remove Air Control Assembly
22 3A0870G
Service
203 207 206 224 209 210
202b
202a
205
222
205
211
212
208
204
212
F IG . 18. Air Controls, Pump System
Meter System Air Controls
214
221
207
Solenoid air
Remove Air/Fluid Panel
1.
Follow Before Servicing , page 13.
2.
Disconnect main air line and solenoid air line. Disconnect fluid lines where they enter the valve stacks.
3.
Remove four screws (8) from sides of frame.
4.
Remove air/fluid panel assembly.
5.
Follow steps in reverse order to reinstall assembly after repair.
Main air
F IG . 19. Remove Air/Fluid Panel
Fluid inlets
8 ti16458a
220
201
212
208
204
212
215
212
219
202 ti16325a
3A0870G 23
Service
Replace Ball Valve
1.
See
Remove Air/Fluid Panel , page 23.
2.
Remove screw (106b) and washer (106c) from the handle on the front of the panel.
3.
Remove fittings (113, 114, 121, 122) and ball valve
(106).
4.
Replace fittings and/or valve as needed.
5.
Follow steps in reverse order to reassemble.
Replace Pressure Gauge(s)
1.
See Remove Air/Fluid Panel , page 23.
2.
Disconnect air line to gauge (105).
3.
Remove mounting screws (105a).
4.
Remove fitting (114) and gauge (105). Replace as needed.
5.
Follow steps in reverse order to reassemble.
112
120
117
105
106b
106c
106a
106
209
122 121
F IG . 20. Air Controls, Meter System
113 114 115 116 114 ti16298a
24 3A0870G
Service
Fluid Controls
108
52
53
4
Remove Dosing Valve Stacks
1.
Follow Before Servicing , page 13.
2.
Meter-based systems: See
3.
Pump-based systems: On inside of panel, remove fluid inlet hose (37). Remove fluid outlet pressure sensor (6). Disconnect fluid fitting (5) from dosing valve stacks (4, 108 if 3-color system). Disconnect fluid outlet lines from fitting (710). Disconnect solvent supply hose from inlet.
6
710
Fluid inlets, meter-based system.
ti16674a
F IG . 22. Remove valve stacks
6.
3-Color System. Remove four bolts (711) from top of valve stack. Separate the two manifolds (701 and
706).
7.
Replace Seat(s): To replace a seat on a single
valve, order Kit 16A560 (see page 49). Remove
dosing valve (705) from manifold (701 or 706), then remove and replace seat (703) and o-rings (702 and
704).
8.
Service Dosing Valve: Order Kit 15U933 (see
page 49). Follow all instructions and warnings in
manual 312782 to rebuild the dosing valve.
9.
Valve Manifold Rebuild: For full service of your valve stack (1-color or 3-color), order Kit 24H254
(see page 49). Follow directions in
37
5
Solvent supply inlet ti16675a
F
IG
. 21. Disconnect fluid lines
4.
Meter-based systems: Disconnect fluid inlet lines
from valve stacks. See F IG . 22.
5.
Remove four bolts (52) and washers (53) from inside the panel to remove each valve stack (4, 108 if 3-color system).
3A0870G 25
Service
Dosing Valve Manifold Rebuild
Order Kit 24H254 (see page 49). Use all parts in the kit.
1.
Follow Steps 1 - 5 in Remove Dosing Valve
2.
Remove fitting (710) and o-ring (708).
3.
Remove the dosing valve (705), then remove seat
(703) and o-rings (702 and 704) from each side of each manifold (701, 706).
4.
3-Color Systems.
Remove the spacer (707) and o-rings (708 and 709) from between the two manifolds (706).
5.
3-Color Systems. Install new o-ring (708) on fitting
(710). Install fitting on bottom of 3-color manifold
(701).
NOTE: Relieve spring tension prior to installing the valve
(705) into the manifold (701 or 706).
6.
Install the small o-ring (702), the seat retainer (703) and the large o-ring (704) into the manifold, then install the valve (705). Torque to 35-40 ft-lb (47-54
N•m). Repeat for each valve.
7.
3-Color Systems. Install new o-ring (708) on the spacer (707). Install new o-ring (709) on the bottom of the 1-color manifold (706). Align manifolds (701 and 706). Install four screws (711). Torque to 8-10 ft-lb (11-14 N•m).
8.
Use four bolts (52) and washers (53) to reattach the valve stacks (4, 108 if present).
9.
10. Reconnect air lines. See System Pneumatic Schematic, pages 52- 53. See also the Tubing Chart and Diagrams
, page 36 for pump-based systems or
page 41 for meter-based systems.
705
702
703
704
706
708
710
F IG . 23. Rebuild Dosing Valve Stacks
711
708
707
709
712
701 ti16302a
26 3A0870G
Service
Repair Flow Meters
Coriolis Meter
1.
Follow Before Servicing , page 13.
2.
To remove and service the Coriolis meter, see manual 313599.
G3000 Meter
Removal
1.
Follow Before Servicing , page 13.
2.
Remove cable harness (118) and fluid lines.
3.
Remove two screws (110) and washers (109) holding the meter (103) and the spacer (104) to the fluid plate (101).
4.
Service meter as instructed in the meter manual
308778.
Installation
1.
Secure meter (103) and spacer (104) to the fluid plate (101) with screws (110) and washers (109).
2.
Connect cable harness (118) and fluid line.
3.
Calibrate meter as instructed in the Operation manual 3A0869.
Repair Mix Manifold
1.
Follow
2.
. 25, page 28. Disconnect fluid lines.
3.
Holding onto the mix manifold (13), remove four screws (52) and washers (53) that hold the mix manifold (13) to the fluid plate (101, meter systems) or to the pump frame (pump systems). Remove the manifold.
4.
Service mix manifold as instructed in Mix Manifold manual 312781.
101
104
13
Disconnect fluid lines.
F IG . 24. Meter System Manifold Removal
118 ti15699a
3A0870G
103
52, 53
109, 110 ti16683a
27
Service
13
Disconnect fluid lines.
F IG . 25. Pump System Manifold Removal ti15697a
52, 53 ti16682a
28 3A0870G
Service
Pump Assembly
16
15
16
Prior to service, remove the displacement pump first, then the air motor.
Remove the Displacement Pump
See pages 30-31 for detailed illustration.
1.
Follow Pressure Relief Procedure , page 9.
2.
Disconnect the fluid line from the pump outlet. See
3.
Merkur Pumps: Remove the tie rod shield (26).
Merkur Bellows Pumps: Remove the coupler shield (79).
4.
Merkur Pumps: Hold the flats of the air motor shaft with a wrench. Use another wrench to loosen the coupling nut (16).
Merkur Bellows Pumps: Hold the coupling nut (16) with a wrench. Use another wrench to turn the motor shaft. To avoid damage to the bellows top cap and the D-shaped seal, do not turn the coupling nut.
16 ti14531a
Disconnect fluid line.
F IG . 26. Loosen the coupling nut
5.
Lower the coupling nut (16) enough to remove the coupling collars (15), and then lift up the motor shaft and remove the coupling nut (16).
ti12812a
14
F IG . 27. Remove the coupling collars
25 ti12813a
6.
Merkur Pumps: Pull up on the TSL reservoir (25) to remove.
7.
Use a socket to remove the tie rod nuts (14).
8.
Carefully remove the displacement pump, with the pump adapter attached.
9.
Clamp the adapter plate in a vise to service the displacement pump.
10. See your displacement pump manual (312792 for
Merkur standard or 312793 for Merkur bellows) for service and parts information.
Remove the Air Motor
1.
Follow
Pressure Relief Procedure , page 9.
2.
Follow Remove the Displacement Pump , page 29.
3.
Disconnect air lines, the reed switch CAN cable, and the linear sensor cable.
4.
Remove four screws (8) then remove the air control
panel (3). See Remove Air Control Assembly , page 22.
5.
Remove four mounting screws (49) and washers
(48) from the under side of the pump frame.
6.
Systems with M02LH0 air motor (2.5 in.):
Remove three screws (49) and washers (48), then remove the adapter plate (17) from the bottom of the air motor.
7.
Carefully lift the air motor up and out. Leave the tie rods and muffler attached or remove them, as you prefer.
3A0870G 29
Parts
Parts
Pump-Based Proportioners, Models 24F088-24F115
9
for control box parts.
58
83
82
39
63
58
10
1
8
64 - connects inside box
3 - See page
controls parts.
valve stack parts.
37
37
38
13 - See page
manifold parts.
30
38
37
19
20
for pump parts.
17
52
4
53
37 ti16324a
3A0870G
Parts
Pumps
62
1
Connects reed switch (54) and linear sensor (62) to AFCM
2
Connects fluid outlet pressure sensor (6) to AFCM (302, see
18
2 6
57
48
49
5
77
37
26
21
24
15
16
25
23
78
37
19
3A0870G
48
49
79
14
20
54 62
54
17
46
55 1
24
15
16
57
22
25
6 2
23
14
78
37
37
5
77 ti16326a
31
Parts
Pump-Based Models 24F088-24F115
-
Ref.
Part Description
10
13
14
15
16
17
18
8
9
5
6
3
4
1
2
-----
-----
-----
-----
FRAME
CONTROL BOX, see page 43, Refs. 301-339
CONTROLS, air; see page 35, Refs. 201-226
VALVE, stack, 1 color/1 solvent; see page 49, Refs. 702-706, 708, and 710
16F164 FITTING, pressure sensor, fluid outlet
15M669 SENSOR, pressure, fluid outlet
----SCREW, machine, serrated flange, hex head, 5/16-18 x 2.25 in.
112547 SCREW, flange, hex head, 1/4-20
109478 NUT
262399
MIX MANIFOLD, dynamic dosing, see page 48, Refs. 601-632
15U606 NUT, lock, m16 x 2
184128 COLLAR, coupling
15T311 NUT, coupler
16F249
ADAPTER, plate, see Table, page 34
AIR MOTOR, Merkur, see Table, page 34, see manual 312796 for repair/parts
2.5 in. (M02xxx) with linear sensor M02LH0
M12LN0
M18LN0
6.0 in. (M12xxx) with linear sensor
7.5 in. (M18xxx) with linear sensor
19
20
21
22
23
LW050A
LW075A
LW100A
LW125A
LW150A
DISPLACEMENT PUMP A, see Table, page 34, see manual 312792 for repair/parts
Merkur, 50cc
Merkur, 75cc
Merkur, 100cc
Merkur, 125cc
Merkur, 150cc
LB100B
LB150B
LW050A
LW075A
LW100A
LW125A
LW150A
DISPLACEMENT PUMP B, see Table, page 34, see manual 312793 for repair/parts
Merkur Bellows with u-cup, 100cc
Merkur Bellows with u-cup, 150cc
Merkur, 50cc
Merkur, 75cc
Merkur, 100cc
Merkur, 125cc
Merkur, 150cc
15M662 ROD, tie, pump A
15M662
15U691
See
Table
ROD, tie, pump B
Merkur pump
Merkur Bellows pump
ADAPTER, displacement pump
24
25
26
27
37
16G463
COUPLING, adapter; see Table, page 34
See RESERVOIR, tsl
Table
24A959 SHIELD, tie rod
-----
USB MODULE, see page 44, Refs. 340-347
HOSE, coupled
206966
239083
3:1, 23:1, and 30:1 systems
45:1 systems
38 166421 FITTING, pipe
39 277853 BRACKET, mounting, display module
40 ▲ 15X214 LABEL, warning, USB, not shown
45 105335 SCREW, machine, pan head, M4 x 0.7, for tie rod guard, not shown
Qty.
2
2
2
6
4
4
1
4
4
2
2
1
2
1
1
1
1
1
2
1
1
4
3
3
1
1
2
1
32 3A0870G
Parts
Ref.
Part Description Qty.
46
115841
C38211
ELBOW, air inlet
M02xxx air motors
All other air motors
15T632
KIT, Air Flow Switch, see page 50, Refs. 900-904, not used on 45:1 systems
2
47 1 or
2
55
57
58
62
51
52
53
54
48
49
100133 WASHER, lock
M02xxx air motors
All other air motors
100680 SCREW, cap, hex hd
M02xxx air motors
All other air motors
101970 PLUG, pipe, hdls, not shown
C19798 SCREW, cap, socket head
100527 WASHER, plain
24A032 SWITCH, reed assembly
16E917 CABLE, IS and reed
120685 GROMMET
115313 PLUG, tube
KIT, LINEAR SENSOR, IS; includes sensor, fitting, magnet with holder, and o-ring
24G849
24G848
M02xxx air motor
All other air motors
63
64
66
67
16E883
123278
-----
-----
MODULE, display
CABLE, CAN, IS, yel m std x f rev.
ELECTRIC POWER ASSEMBLY, Models 24F088-24F101, see page 45, Refs. 401-411
ALTERNATOR POWER ASSEMBLY, Models 24F102-24F115, see page 46, Refs.
501-517
68 ▲ 15W776 LABEL, warning, not shown
77 156971 FITTING, nipple, short
1
1
1
1
1
2
78
16H491
512351
ADAPTER
M02xxx air motor
All other air motors
24A640 SHIELD, Bellows 79
82
83
84
111307 WASHER, shipped loose, for Display Module
121224 SCREW, shipped loose, for Display Module
16G475 MAGNET, with holder
87 16F793 CARD, alarm/icon, not shown
325 ▲ 15W598 LABEL, warning
2
1
1
2
2
2
2
14
8
2
2
2
3
12
2
14
8
4
12
--- Not sold separately.
▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.
3A0870G 33
Parts
Parts that Vary by Model, Pump-Based
Model
Non-IS IS
Adapter
Plate
(Item 17)
Air
Motor
(Item 18)
“A”
Lower
(Item 19)
“B”
Lower
(Item 20)
“A”
Tie Rod
(Item 21)
“B”
Tie Rod
(Item 22)
Lower
Adapter
(Item 23)
Coupling
(Item 24)
TSL
Reservoir
(Item 25)
24F088 24F102 16F249 M02LH0 LW125A LW125A 15M662 15M662 15T394 16G463
24F089 24F103 ----M12LN0 LW100A LW100A 15M662 15M662 15T393 -----
24A627
24A626
24F090 24F104
24F091 24F105
-----
-----
M12LN0
M12LN0
LW075A LW075A 15M662 15M662
LW050A LW050A 15M662 15M662
15T392
15T391
-----
-----
24A625
24A622
24F092 24F106 16F249 M02LH0 LW150A LB150B 15M662 15U691 15T395 16G463
24F093 24F107 ----M12LN0 LW100A LB100B 15M662 15U691 15T393 -----
24A628
24A626
24F094 24F108 ----M18LN0 LW100A LB100B 15M662 15U691 15T393 ----24A626
24F095 24F109 16F249 M02LH0 LW125A LW125A 15M662 15M662 15T394 16G463 24A627
24F096 24F110
24F097 24F111
-----
-----
M12LN0 LW100A LW100A 15M662 15M662 15T393
M12LN0 LW075A LW075A 15M662 15M662 15T392
----24A626
----24A625
24F098 24F112 ----M12LN0 LW050A LW050A 15M662 15M662 15T391 ----24A622
24F099 24F113 16F249 M02LH0 LW150A LB150B 15M662 15U691 15T395 16G463 24A628
24F100 24F114
24F101 24F115
-----
-----
M12LN0 LW100A LB100B 15M662 15U691 15T393
M18LN0 LW100A LB100B 15M662 15U691 15T393
----24A626
----24A626
34 3A0870G
Parts
Air Controls, Pump-Based Models 24F088-24F115
203 207 223
206 224 209 210
202b
202a
205
222
205
211
212
208
204
212
214
221
207
220
201
212
208
204
212
215
212
219
202 ti16325a
Ref.
Part Description
201 ----PLATE, air controls
202 110225 VALVE, vented, 2-way
202a -----
202b -----
HANDLE
NUT, handle
202c 290167 TAG, warning, not shown
203 15T500 GAUGE, air pressure
203a ----SCREW, mounting, gauge
204 116513 REGULATOR, air
205 116514 NUT, air regulator
206 15D795 FILTER, air
206a 15D890 ELEMENT, 40 micron
207 ----ELBOW, male
208 15T866 ELBOW, swivel, 1/8 npt x 5/32 T
209 114124 FILTER, air
209a 15D909 ELEMENT, 5 micron
Qty.
1
2
2
2
1
1
1
6
2
1
3
1
1
1
1
Ref.
Part Description
210 114153 ELBOW
211 15T498 ELBOW
212 115841 ELBOW
214 114469 ELBOW
215 502524 CONNECTOR, tube
219 113498 VALVE, safety
220 114485 CONNECTOR, male, 3/8 npt
221 16F701 MANIFOLD, pump
222 551787 SCREW, cap
223 109478 NUT, lock
224 100022 SCREW, cap, hex
Qty.
1
1
1
4
2
2
5
1
1
1
3
3A0870G 35
Parts
Tubing Chart, Pump-Based Models 24F088-24F115
Type
Air
Air
Air
Air
Fluid
Fluid
Fluid
Fluid
Air
Air
Air
Air
Air
Air
Air
Air
Air
Color Description
* Used only on IS models.
Starting Point Ending Point Tube OD in. (mm)
Green Solvent Valve A On
Green Dose Valve A On
Green Solvent Valve B On
Green Dose Valve B On
Red Solvent Valve A Off
Red
Red
Dose Valve A Off
Solvent Valve B Off
----
----
----
----
Red Dose Valve B Off
Natural Solenoid Air
Natural Air Regulator to Pump B
Natural Air Regulator to Pump A
Pump B to Valve Stack B
Pump A to Valve Stack A
Natural Air Regulator to Alternator*
Black Alternator Air Exhaust*
A4
A5
Valve Stack A to Mix Manifold A6
Valve Stack B to Mix Manifold A7
A8
A9
4R
A1
A2
A3
1G
2G
3G
4G
1R
2R
3R
1G
2G
3G
4G
1R
2R
3R
4R
A1
A2
A3
A4
A5
A6
A7
A8
A9
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.25 (6.3)
0.375 (9.5)
0.375 (9.5)
-----
-----
-----
-----
0.375 (9.5)
0.5 (12.7)
1R 2R 3R 4R
*
IS Models
1G 2G 3G 4G
GFB1-S
ATOM-1 ti13861a
GFB1-C ti16770a
GFB1-P
(Pressurized air line)
GFB1-A
A8*
A9* ti16771a
GFB1-C
GFB1-S ti13863a
36 3A0870G
Parts
GFB1-A
ATOM-1
ATOM-2
A2
B Side
A1
A3
A Side
A3 ti16772a
2G
2R
4G
4R
1R
1G
A5
A Side ti16765a
A5
See Manual 312784 for full setup instructions for a gun flush box.
A6
A Side B Side ti16764a
A7
A4
3R
3G
B Side
A4 ti16766a
3A0870G 37
Parts
Meter-Based Proportioners, Models 24F080-24F087
for control box parts.
9
39
82
83
63
58
1
10
105
68 53
52
37
111
103
64 - connects inside box
for valve stack parts.
118 104
38
118
103 104 111
37
53
38
102
13 - See page
manifold parts.
52
101
106
8
109
110
for valve stack parts.
ti16297a
3A0870G
Parts
117 105
112 120
106b
106c
106a
106
209 ti16298a
122 121 113 123
Meter-Based Models 24F080-24F087
115 116 114
Ref.
Part Description
83
87
90
101
102
103
104
1
2
4
8
9
10
13
-----
-----
-----
-----
FRAME, meter
CONTROL BOX, see page 43, Refs. 301-339
VALVE, stack, 1 color/1 solvent; see page 49, Refs. 702-706, 708, and 710
1-Color Models
3-Color Models
SCREW, machine, serrated flange, hex head, 5/16-18 x 2.25 in.
112547 SCREW, flange, hex hd
109478 NUT
262398
MIX MANIFOLD, sequential dosing, see page 48, Refs. 601-623
27
35
37
38
-----
117356
206966
114339
USB MODULE, see page 44, Refs. 340-347
VALVE, solenoid (3-color models; see page 43)
HOSE, coupled, 1.5 ft
FITTING, union, swivel, 1/4 npt, sst
39 277853 BRACKET, mounting, display module
40
▲
15X214 LABEL, warning, USB, not shown
47 15T632
KIT, Air Flow Switch, see page 50, Refs. 900-904
52
53
57
58
C19798 SCREW, cap, socket head
100527 WASHER, plain
120685 GROMMET
115313 PLUG, tube
63
64
66
67
16E883
123278
-----
-----
MODULE, display
CABLE, IS, CAN, yellow, m std x f rev.
ELECTRIC POWER ASSEMBLY, Models 24F080-24F083, see page 45, Refs. 401-411
ALTERNATOR POWER ASSEMBLY, Models 24F084-24F087, see page 46, Refs.
501-517
68
▲
15W776 LABEL, warning
82 111307 WASHER, shipped loose, for Display Module
121224 SCREW, shipped loose, for Display Module
16F793 CARD, alarm/icon, not shown
16G607 BUSHING, strain relief
----PLATE, fluid
114342 ELBOW, 1/4-18 npsm
289813 METER, gear, G3000
16F063 SPACER, meter
3A0870G
Qty.
4
4
2
1
4
1
2
2
1
1
2
2
1
1
2
1
1
1
1
2
2
1
1
4
1
2
2
1
1 or 2
12
12
39
Parts
Ref.
Part Description
110
111
112
113
114
115
116
117
105 15T500 GAUGE, air pressure
105a ----SCREW, mounting, gauge
106 118762 VALVE, ball, vented, 1/2 in.
106a ----HANDLE, ball valve
106b -----
106c -----
108
109
-----
SCREW
WASHER
VALVE, stack, 3 clr/1 fl, see page 49, 3-Color Models only
100527 WASHER, plain
117029
501867
107404
100081
SCREW, M6x25
VALVE, check
SCREW, cap, sockethead
BUSHING, pipe
C19675 BUSHING, reducer
15T498 SWIVEL, 90°, 5/32T x 1/8 npt(f)
C20365 FITTING, tee
517312 CONNECTOR, male
118
120
121
122
258528 HARNESS, cable, w/connector, G3000
114153 ELBOW, male, swivel
158491 FITTING, nipple
512905 FITTING, bulkhead
123
124
114366 FITTING, tube
117793 HOLDER, tie
209 114124
FILTER, air, 3/8 npt, see page 51 for filter elements.
230 262028 TOOL KIT, installation
325 ▲ 15W598 LABEL, warning
▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.
Qty.
1
1
2
1
2
1
4
2
1
4
1
1
1
6
1
1
1
1
1
6
1
1
1
2
1
40 3A0870G
Parts
Tubing Chart, Meter-Based Models 24F080-24F087
Type
Air
Air
Air
Air
Air
Air
Air
Fluid
Air
Air
Air
Air
Air
Air
Air
Air
Fluid
Air
Air
* Used only on IS models.
Color Description
Starting
Point
Green
Green
Green
Green
Green
Green
Red
Red
Solvent Valve A On
Dose Valve A1 On
Solvent Valve B On
Dose Valve B On
Dose Valve A2 On
Dose Valve A3 On
Solvent Valve A Off
Dose Valve A1 Off
Red
Red
Red
Red
Solvent Valve B Off
Dose Valve B Off
Dose Valve A2 Off
Dose Valve A3 Off
----Main Air to Pressure Gauge A1
Natural Solenoid Air A2
Natural
-----
Main Air to Filter
Valve Stack A to Meter A
A3
A4
3R
4R
5R
6R
5G
6G
1R
2R
1G
2G
3G
4G
-----
Black
Valve Stack B to Meter B
Alternator Air Exhaust*
A5
A6
Natural Air Regulator to Alternator* A7
Ending
Point
1G
2G
3G
4G
5G
6G
1R
2R
3R
4R
5R
6R
A1
A2
A3
A4
A5
A6
A7
Tube OD in. (mm)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.25 (6.3)
0.25 (6.3)
0.375 (9.5)
0.375 (9.5)
0.5 (12.7)
0.375 (9.5)
*
IS Models
A1 ti13861a
A3 ti16773a
GFB1-S
ATOM-1
GFB1-P
(Pressurized air line)
GFB1-A
1R 2R 3R 4R 5R 6R
GFB1-C
GFB1-S ti13863a ti16771a
1G 2G 3G 4G 5G 6G GFB1-C ti16770a
A7*
A6*
3A0870G 41
Parts
See Manual 312784 for full setup instructions for a gun flush box.
A4 A5
A Side
GFB1-A
ATOM-1
ATOM-2
A2
1G
2G
2R
5R
5G
A Side
42
6R 1R 6G
A5 ti16768a
B Side ti16767a
4G
4R
B Side
3G
3R ti16769a
3A0870G
Parts
Control Box
306 310 309
304
301
313
315
338 - 3-color models have
2 additional solenoids here.
329
307 305 308 ti16421a
318
330
68
325
314 321 303
Ref.
Part
68 ▲ 15W776 LABEL, warning
301 -----
Description
ENCLOSURE, control box
Qty.
302 16F357 MODULE, advanced fluid control 1
302a 103854 SCREWS, access cover, not shown 2
302b ----COVER, access, not shown
1
1
1
303
304
305
110637 SCREW, machine, panhead
16E943 MANIFOLD, solenoid
121628 SCREW, self-sealing
306 117356 VALVE, solenoid
4
1
2
Pump and 1-Color Meter Systems
3-Color Meter Systems
307 114263 CONNECTOR, male
Pump and 1-Color Meter Systems
4
6 not shown
313 113796 SCREW
314 ----PLUG, hole
8
3-Color Meter Systems
308 100139 PLUG, pipe
309 C06061 MUFFLER, 2
310 112698 ELBOW 1
311 122000 ALARM, 1
312 15V778 CABLE, IS, CAN female-female, 1
12
4
2
2
320
302
316
339 317
326
311 ti16303a
Ref.
Part Description Qty.
315 102040 NUT, lock, hex
316 117625 NUT, locking
317 117745 BUSHING, strain relief
2
1
1
318 119257 CONNECTOR, bar, ground
319 16G607 BUSHING, strain relief
320 16E890 HARNESS, solenoid/meter
321 24F208 COVER, control box
325 ▲ 15W598 LABEL, warning
326 116343 SCREW, ground
1
1
327 223547 WIRE, not shown
1
A/R
328 112512 FERRULE, wire, orange, not shown 10
329 117793 HOLDER, tie 3
330 103833 SCREW, machine
338 552183 PLATE, solenoid mounting; 3-color
2
2
1
1
2 models have solenoids on this plate.
339 195889 CONNECTOR, cord strain relief
340 15D906 SUPPRESSOR
1
1
▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.
3A0870G 43
Parts
USB Module
Purchase cable separately.
See CAN Cable options below.
342
341
349
342
343
345
348
346
340 ti16427a
Ref.
Part Description
340 16F358 USB MODULE with TOKEN
341 121417 SCREW
342 102063 WASHER
343 195875 SCREW, grounding
345 24H084 USB HARNESS
346 15R325 COVER, bulkhead
347 15X214 LABEL, warning
348 16G873 BRACKET, grounding
349 195874 SCREW, grounding
CAN Cables
Part Description
15V782 CABLE, for Non-IS models
15V778 CABLE, for IS models
Qty.
1
1
Software Updates
Part Description
16D922 TOKEN, latest version of software for
Advanced Fluid Control Module,
Display Module, and USB Module
Qty.
1
Qty.
1
1
1
1
1
2
1
1
4
NOTE: Order Kit 24H253 to add a USB Module.
Includes all parts shown and instructions.
44 3A0870G
Parts
Electric Power Assembly
402
401
405
407
410
Ref.
Part Description Qty.
401 15V747 POWER SUPPLY, 24 VDC, 2.5 A, 1
402
403
60 watt, B-code, with cable
116320 SWITCH, rocker, power
115306 FILTER, power line
404 114095 BLOCK, terminal
405 112144 SCREW, machine, pan head
406
407
109467 SCREW, machine, pan head
103832 SCREW, mach
408 100139 PLUG, pipe, not shown
410 ----HARNESS, 2-wire; 8 in. (203 mm)
1
1
411 -----
2
2
HARNESS, 3-wire; 4 in. (102 mm) 1
1
4
1
1
----- Not sold separately.
403
411
404
406 ti16454b
NOTE: Order Electric Power Conversion Kit 16G351 to convert an intrinsically safe air-powered alternator power supply to a non-intrinsically safe electric power supply.
3A0870G 45
Parts
Alternator Power Assembly
511
501
J1
Connect cable
517 to fluid control module.
510
509
508
504
505
J2
Connect cable 516 to USB module, if present.
J3
Connect cable 515 to display module.
Ref.
Part Description
501 255728 ALTERNATOR, module, see page
502 15W017 VALVE, safety
503 156971 FITTING, nipple, short
504 115841 ELBOW
505 115243 REGULATOR, air, 1/4 npt
506 113915 UNION, swivel
507 112307 ELBOW
508 104655 GAUGE, pressure
509 103833 SCREW, machine
510 100284 NUT, hex
511 15B090 WIRE, grounding
512 112514 FERRULE, not shown
513 ----TUBE, exhaust, black; 1/2 in.
514 -----
(13 mm) OD
TUBE, air; 3/8 in. (10 mm) OD
Qty.
1
1
1
1
1
1
1
1
1
1
1
4
1
3
506
CAN Cables
503 507
502 ti16300b
Ref.
Part Description
515 123278 CABLE, CAN; 10 ft (3.05 m)
516 15V782 CABLE, CAN; 2 ft (0.6 m)
517 15V778 CABLE, CAN; 20 in. (0.5 m)
Qty.
1
1
1
NOTE: Order Alternator Conversion Kit 16G353 to convert from an electric power supply to an air-powered alternator power supply.
46 3A0870G
Parts
Alternator Module 255728
501k
501j
501f
501h
501a
501b
Ref.
Part Description
501a -----
501b -----
501c -----
HOUSING, upper and lower
GASKET, stacked, internal
GASKET, housing
501d 257147 TURBINE
501e ----BOARD, assy.
501f 122161 FITTING, air
501g ▲ 15R337 LABEL, warning, not shown
501h 114380 SCREW, cap, socket head
591j 122848 FITTING, air
501k
▲
172953 LABEL, grounding
Qty.
1
1
1
1
1
1
1
7
1
1
501d
501e
501c
501a
3A0870G 47
Parts
Sequential Dosing Mix Manifold 262398
604
623
622
Dynamic Dosing Mix Manifold 262399
605
625
602
611
613
618
628
607
621
620
611
614
619
603
616
631
630
627
615
617
632
601
611
626
617
616
611
606
615
603
619
614
608
618
613
611
610 609 617 601 602 605 ti16301a
Ref.
Part Description
601 ----BODY, integrator manifold
602 15T592 PLUG, integrator manifold
603 ----O-RING
604 118823 TUBE, outlet
605 15B588 SCREW, cap, socket hd
606 15D430 TUBE, static mixer
607 118822 ELEMENT, static mixer
608 118830 CLAMP, body, integrator tube
609 118831 COVER, clamp, integrator tube
610 101885 SCREW, cap, socket hd
611 ----O-RING
613 15T943 BASE, integrator
614 ----MANIFOLD, end
615 15T748 SEAL, screw
616 15T749 SEAL, screw
617 ----O-RING
618 ----O-RING
619 16D658 VALVE, check
620 15V021 MIXER, integrator, 50cc, includes
621 -----
622 -----
623 ----parts 621-623
HOUSING, integrator, 50cc
CAP, mix, integrator
CAP, integrator
Qty.
1
1
1
1
2
2
1
3
1
1
2
1
2
1
2
1
8
1
2
1
1
1
617
606
624
629 ti16327a
Ref.
Part Description
601 ----BODY, integrator manifold
602 15T592 PLUG, integrator manifold
603 ----O-RING
605 15B588 SCREW, cap, socket hd
606 15D430 TUBE, static mixer
607 118822 ELEMENT, static mixer
611 ----O-RING
613 15T943 BASE, integrator
614 ----MANIFOLD, end
615 15T748 SEAL, screw
616 15T749 SEAL, screw
617 -----
618 -----
O-RING
O-RING
619 16D658 VALVE, check
624 15U955 CAP, injection, 0cc, includes part
625 -----
625
RESTRICTOR, injection, 0.070
626 16G872 BRACKET, mounting
627 105510 WASHER, lock
628 100609 SCREW, machine, panhead
629 118830 CLAMP
630 118831 COVER, clamp
631 101885 SCREW, cap, sockethead
632 112223 NUT, hex
Qty.
2
1
2
1
2
1
1
2
8
1
1
1
2
3
1
1
1
2
2
2
1
2
2
48 3A0870G
Parts
705
702
703
704
706
706
711
708
710
708
707
709 ti16791a
1-Color/1 Solvent Valve Stack
Ref.
Part Description
702* -----
703* -----
704* -----
O-RING
SEAT, valve
O-RING, PTFE
705 15X303 VALVE, dispense
706 16F057 MANIFOLD, valve, 1-color
708* ----O-RING
710 16F064 FITTING, CC
Qty.
2
1
2
1
2
2
2
--- Parts not sold separately.
* Parts included in Valve Stack Rebuild Kit 24H254.
This kit includes wear parts for 1-color and 3-color valve stacks. Order Kit 16A560 to replace a single seat (includes 702-704). Order Kit 15U933 to repair a single dispense valve.
NOTE: Order Kit 24H255 to convert an existing 1-color system to a 3-color system.
705
702
703
704
708
710
712
701 ti16302a
3-Color/1 Solvent Valve Stack
Ref.
Part Description
701 16F058 MANIFOLD, valve, 3-color
702* -----
703* -----
O-RING
SEAT, dump valve
704* ----O-RING, PTFE
705 15X303 VALVE, dispense
706 16F057 MANIFOLD, valve, 1-color
707* ----SPACER, manifold
708* -----
709 -----
O-RING
O-RING
710 16F064 FITTING, CC
711 100642 SCREW, cap, socket hd
712 101970 PLUG
Qty.
1
1
4
4
1
4
4
1
4
2
1
4
--- Parts not sold separately.
* Parts included in Valve Stack Rebuild Kit 24H254.
This kit includes wear parts for 1-color and 3-color valve stacks. Order Kit 16A560 to replace a single seat (includes 702-704). Order Kit 15U933 to repair a single dispense valve.
3A0870G 49
Parts
812
807
807
808
801
Air Flow Switch Kit 15T632
903
904
900
901
902
809
810
811
802
803
804 ti16426a
Pump Stand Kit 24F301
Meter Stand Kit 24G611
Ref.
Description
801 TUBE, cart
802 PLUG, tube
803 CASTER, cart
804 CASTER, swivel
805 NUT
806 WASHER
807 WASHER
808 SCREW, cap, hex hd‘
809 PLUG, button
810 NUT
811 WASHER
812 ADAPTER, meter stand only
Qty.
16
8
8
8
2
2
2
4
4
1
4
4
NOTE: Stand parts are not sold separately.
Ref.
Part Description
900 119159 SWITCH, air flow
901 ----FITTING
902 -----
903 -----
904 -----
ELBOW, 1/4 npt
NIPPLE, 1/4 x 1/4 npt
CONNECTOR, tube ti16428a
Qty.
1
1
1
1
1
50 3A0870G
Accessories
Accessories
ProMix 2KE systems are not approved for use in hazardous locations unless the base model, all accessories, all kits, and all wiring meet local, state, and national codes.
Part Description
USB Module
16F358
Air Flow Switch
15T632
Power Kits
16G351
Electric Power Kit, see page 45
16G353
Alternator Power Kit, see page 46
Cables
123278 10 ft (3.05 m), Yellow, IS CAN Cable, male x female
123280 50 ft (15.25 m), Yellow, IS CAN Cable, male x female
15U533 50 ft (15.25 m) IS CAN Cable, Blue, female x female
Air Filter Kits
15D909 5 micron air filter replacement
15D890 40 micron air filter replacement
Stand Kits
24F301
24G611
Dosing Kits
15V021 50cc Sequential Dosing
24B618 100cc Sequential Dosing
15U955 0cc Dynamic Dosing
Meter Kits
15V806 1/8 in. Coriolis Kit
16D329 S3000 Solvent Meter Kit
Gun Flush Box
15V826 Gun Flush Box
3-Color Conversion Kit
24H255 Convert a Meter System from
1 Color/1 Solvent to 3 Colors/1 Solvent
Part Description
Gun Holder Kits (for GFB)
198787 ProXS2
198405 ProXs3, ProXs4
196768 PRO 3500, 3500hc, 4500
15T646 AirPro Air Spray
196769 Delta Air Spray
196770 Alpha
196771 Alpha Plus, Alpha Plus RAC
15G093 G15
15G346 G40, G40 RAC
Pump Accessory Kits
256410 Hopper, 1.5 gallon (1 l) polyethylene)
243340 5 gal (18.9 l) pail cover with agitator
222121 Fluid regulator, stainless steel
Maximum working pressure: 1500 psi (10.3
MPa, 103 bar)
Regulator range: 150 - 1200 psi (1.0-8.2
MPa, 10-82 bar)
24A587 Pump outlet fluid filter, stainless steel, 60 mesh (250 micron), 5000 psi (35 MPa, 350 bar)
256425 Fluid filter drain valve, stainless steel, 5000 psi (35 MPa, 350 bar)
224458 Fluid filter screen element, 3-pack, 30 mesh, stainless steel
224459 Fluid filter screen element, 3-pack, 60 mesh, stainless steel
24A954 55 gal Drum Suction Hose and Strainer, 3/4 in. fluid inlet
24B598 55 gal Drum Suction Hose and Strainer, 1 in. fluid inlet
24B337 Stand Mount Suction Hose, PTFE lined,
3/4 in. inlet
24B338 Stand Mount Suction Hose, PTFE lined, 1 in. inlet
24B424 Wall Mount Suction Hose, PTFE lined, 3/4 in. inlet
24B425 Wall Mount Suction Hose, PTFE lined, 1 in. inlet
3A0870G 51
Schematics
Schematics
Hazardous Location System Pneumatic Schematic
UBE
CLOSE
5/3
OPEN
UBE
CLOSE
5/3 OPEN
UBE
CLOSE
5/3
OPEN
UBE
CLOSE
5/3
OPEN
UBE
CLOSE
5/3 OPEN
UBE
CLOSE
5/3
OPEN
UBE
5/3
OPEN
)
AIR INPU
52 3A0870G
Non-Hazardous Location Pneumatic Schematic
CLOSE
UBE
T
5/3
OPEN
CLOSE
UBE
T
5/3
OPEN
CLOSE
UBE
T
5/3
OPEN
CLOSE
UBE
T
5/3
OPEN
CLOSE
UBE
T
5/3
OPEN
UBE
CLOSE
T
5/3 OPEN
UBE
T
5/3 OPEN
Schematics
3A0870G
)
AIR INPU
53
Schematics
Hazardous Location Electrical Schematic
18 PSI
1.5 FCM
( MIN )
GRND
AL T ERNA T OR
MODULE
4
3
5
2
1
J 2
4
3
5
2
1
J3
4
3
5
2
1
J1
CAN
+V_
_ L
CAN
V_ CAN _ R
CAN _ H
SHIELD
T N
CAN
+V_
_ L
CAN
V_ CAN _ R
CAN _ H
SHIELD
T N
CAN
+V_
_ L
CAN
V_ CAN _ R
CAN _ H
SHIELD
T N
MEMBRANE
CAN
+V_
_ L
CAN
V_ CAN
CAN _ H
SHIELD
_ R T N
TT
TT
TT
TT
ON
ON
ON
ON
_
_
_
TT
TT
ON
TT
TT
ON
ON
_
_
_
_
TT
TT
TT
TT
ON
ON
ON
ON
_
_
_
_
BU
BU
BU
BU
BU
BU
BU
BU
BU
BU
BU
BU
COM
SHIELD
S
DOWNARW
UPARW
CLEAR
T OP
FUNC 4
S
FUNC 1
T AR T
RIGH T
LEF T
ARW
ARW
EN T ER
( BU
_ FUNC2
TT ONS )
3
LED
LED
LED _
_
_
YELLOW
BLUEA
GREEN
UNUSED
LED _ BLUEB
UNUSED
LED _ RED
UNUSED
COM ( LEDS )
UNUSED
UNUSED
UNUSED
UNUSED
J6
J1
13
2
14
9
10
1
11
8
7
6
5
4
3
2
1
J4
4
3
5
2
1
8
7
9
6
5
4
3
2
1
J 2
4
3
2
1
USER IN T ERFACE
MODULE
CAN
+V_
_ L
CAN
V_ CAN _ R
CAN _ H
SHIELD
T N
P 3
4
3
5
2
1
USB BASE
MODULE
4
3
5
2
1
J7
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
ALARM
-
+
FLOW ME T ER A
AIR FLOW SWI T CH 1
GFB 1 PRESSURE SWI T CH /
AIR FLOW SWI T CH 2
PURGE A
DOSE A 1
PURGE B
DOSE B
DOSE A2
DOSE A 3
GFB #1
MANIFOLD
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
3X CABLE
PWR ( RED )
COM ( BLACK )
SIG ( WHI T E )
SHIELD / GRN
SIG
COM
SIG
COM
3X CABLE
FLOW ME T ER B
PWR ( RED )
COM ( BLACK )
SIG ( WHI T E )
SHIELD / GRN
4
3
5
2
1
P 4
2
2
30
9
8
7
6
5
4
3
2
2
2
2
2
2
2
22
1
0
16
17
18
19
13
2
14
15
9
10
1
11
8
7
6
5
4
3
2
1
P 1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
CAN
CAN
V
L
H
CAN
V CAN
R
R T
T
BI T 0
BI T 1
VT OKEN
/
LOFO
/
HOLD
CS
V CAN
V CAN
V CAN
V
V
CHASSIS
V
CAN
CAN
CAN
R
R
CHASSIS
R
T
T
T
N
N
GND
V CAN R
T
GND
N
N
BI
BI
T 3
T
GND
SCK
SO
2
SI
V
V
V
V
CAN
CAN
CAN
CAN
V CAN R
R T
T
N
N
N
N
J 2
2
2
30
9
8
7
6
5
4
3
2
2
2
2
2
2
2
22
1
0
16
17
18
19
13
2
14
15
9
10
1
11
8
7
6
5
4
3
2
1
USB COMPONEN T
MODULE
9
10
11
1 2
13
14
7
8
5
6
3
4
1
2
9
10
11
1 2
13
14
7
8
5
6
3
4
1
2
GROUND
T ERMINAL
54 3A0870G
1
14
1
14
Hazardous Location Electrical Schematic (continued)
" A " PRESSURE
T RANSDUCER
V_
CAN
+V_
CAN _
CAN
R T
_
_
CAN
N
H
SHIELD
L
UNUSED
ALARM (+)
COMMON
PURGE A (+)
DOSE A 1 (+)
FLOW
+1
ME T ER
2
A
AI
V DC
SIG
COMMON
DOSE
DOSE
A2
A
(+)
3 (+)
+5 V
AI
COMMON
SHIELD
DC
(-)
(+)
REED
LINEAR
SWI
REED
T
T CH
REED SWI
LINEAR
CH
SWI
LINEAR
_
SENS
B T
SENS "
M (
T
SENS
"
UNUSED
DOWN )
_T OP
CH
" A
A
_
"
"
(
A " +5 V
SIG
UP
COM
DC
COM
UNUSED
)
.
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J14
7
8
5
6
3
4
1
2
J 2 5
3
4
1
2
J 2 5
3
4
1
2
J1 2
3
4
1
2
5
J 2
3
4
1
2
5
J8
3
4
1
2
5
J4
3
4
1
2
5
FLUID
CON T ROL
MODULE
" A " REED
SWI T CH
FERRI T E
" A " LINEAR
SENSOR
3
4
1
2
J11
7
8
5
6
3
4
1
2
J15
3
4
1
2
J11
3
4
1
2
5
J3
3
4
1
2
5
J13
3
4
1
2
5
J7
3
4
1
2
5
J5
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
AFS #1 (+)
COMMON
PURGE B (+)
DOSE B (+)
+1 2 V DC
FLOW ME T ER B SIG
COMMON
GFB INPU T/ AFS # 2 (+)
GFB OU T PU T
+5 V DC
AI (-)
COMMON
AI (+)
SHIELD
LINEAR SENS " B
UNUSED
REED SWI
REED SWI T
T CH _ B
" SIG .
REED SWI T
LINEAR
LINEAR
UNUSED
T M
CH _T OP (
( DOWN
UP )
)
CH
SENS
SENS
"
"
_
B
B
COM
" +5 V
" COM
DC
" B " PRESSURE
T RANSDUCER
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
" B " REED
SWI T CH
" B " LINEAR
SENSOR FERRI T E
Schematics
3A0870G 55
Schematics
Non-Hazardous Location Electrical Schematic
TERMINAL
BLOCK
L N GRND
L GRND N
LINE POWER
FILTER
L N
2A
2
SWITCH
ROCKER
1A
1
POWER
SUPPLY
4
3
5
2
1
J 1
CAN_L
+ V _CAN
V _CAN_RTN
CAN_H
SHIELD
MEMBRANE
CAN_L
+ V _CAN
V _CAN_RTN
CAN_H
SHIELD
BUTTON_DOWNARW
BUTTON_UPARW
BUTTON_CLEAR
BUTTON_STOP
BUTTON_FUNC 4
BUTTON_FUNC1
BUTTON_START
BUTTON_RIGHTARW
BUTTON_LEFTARW
BUTTON_ENTER
BUTTON_FUNC
BUTTON_FUNC2
COM ( BUTTONS
SHIELD
)
3
LED_YELLOW
LED_BLUEA
LED_GREEN
UNUSED
LED_BLUEB
UNUSED
LED_RED
UNUSED
COM ( LEDS )
UNUSED
UNUSED
UNUSED
UNUSED
J6
J 1
J4
8
7
9
6
5
4
3
2
1
8
7
6
5
4
3
2
1
1
9
0
11
1
1
12
3
4
4
3
5
2
1
J 2
4
3
2
1
USER INTERFACE
MODULE
CAN_L
+ V _CAN
V _CAN_RTN
CAN_H
SHIELD
P 3
4
3
5
2
1
USB BASE
MODULE
4
3
5
2
1
J7
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
ALARM
-
+
FLOW METER A
AIR FLOW SWITCH 1
GFB 1 PRESSURE SWITCH /
AIR FLOW SWITCH 2
MANIFOLD
PURGE A
DOSE A1
PURGE B
DOSE B
DOSE A2
DOSE A 3
GFB # 1
3X CABLE
PWR ( RED )
COM ( BLACK )
SIG ( WHITE )
SHIELD / GRN
SIG
COM
SIG
COM
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
RED
3X CABLE
FLOW METER B
PWR ( RED )
COM ( BLACK )
SIG ( WHITE )
SHIELD / GRN
4
3
5
2
1
P 4
2
2
2
2
2
22
4
3
1
1
2
21
0
9
1
1
1
1
8
7
6
5
2
2
30
9
8
7
6
5
1
12
4
3
1
9
11
0
8
7
6
5
4
3
2
1
P1
CAN_L
+ V _CAN
V _CAN_RTN
CAN_H
SHIELD
CAN RTN
CAN L
CAN H
V CAN RTN
V CAN RTN
BIT 0
BIT 1
V TOKEN
/
LOFO
/
HOLD
CS
V CAN
V CAN
V CAN
V CAN RTN
V CAN RTN
CHASSIS GND
CHASSIS GND
V CAN RTN
V CAN RTN
BIT 3
BIT 2
GND
SI
V
SCK
SO
V
V
CAN
CAN
V
CAN
V
CAN RTN
J 2
2
2
2
2
2
22
4
3
1
1
2
21
0
9
1
1
1
1
8
7
6
5
2
2
30
9
8
7
6
5
1
12
4
3
1
9
11
0
8
7
6
5
4
3
2
1
USB COMPONENT
MODULE
9
1 0
11
12
1 3
1 4
5
6
7
8
1
2
3
4
9
1 0
11
12
1 3
1 4
7
8
5
6
3
4
1
2
GROUND
TERMINAL
56 3A0870G
Non-Hazardous Location Electrical Schematic (continued)
1
2
8
9
5
6
11
2
13
8
9
11
1 2
4
5
1
2
V_
CAN _ L
+V_ CAN
CAN _ R T N
CAN _ H
SHIELD
UNUSED
ALARM
PURGE
(+)
COMMON
DOSE
A (+)
A 1 (+)
FLOW
+1
ME T ER
DOSE
DOSE
2
A2
A
A
V DC
SIG
COMMON
(+)
3 (+)
" A " PRESSURE
T RANSDUCER
+5 V
AI
DC
(-)
COMMON
AI (+)
SHIELD
REED
LINEAR
SWI
REED
T
REED SWI
LINEAR
SWI
CH
LINEAR
_
T
SENS
B T
CH
SENS "
M (
SENS
T
_T
"
UNUSED
DOWN
OP (
CH
A " +5 V
" A
A
_
"
" SIG
UP
COM
DC
COM
UNUSED
)
)
.
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J8
J4
J1 2
4
3
5
2
1
4
3
5
2
1
4
3
5
2
1
J 2
4
3
5
2
1
J14
8
7
6
5
4
3
2
1
J 2 5
4
3
2
1
J 2 5
4
3
2
1
FLUID
CON T ROL
MODULE
" A " REED
SWI T CH
" A " LINEAR
SENSOR
J7
4
3
5
2
1
J5
4
3
5
2
1
4
3
5
2
1
J13
4
3
5
2
1
J3
8
7
6
5
4
3
2
1
J15
4
3
2
1
J11
4
3
2
1
J11
CAN _ L
+V_
V_
CAN
CAN
CAN _ H
SHIELD
_ R T N
UNUSED
AFS #1 (+)
COMMON
PURGE B (+)
DOSE B (+)
+1 2 V DC
FLOW ME T ER B SIG
COMMON
GFB INPU
GFB OU T
T/
PU T
AFS # 2 (+)
+5 V DC
AI (-)
COMMON
AI (+)
SHIELD
LINEAR SENS "
UNUSED
REED SWI
REED
REED
SWI
SWI
LINEAR
LINEAR
UNUSED
T
T
T CH
CH
CH
SENS
SENS "
"
_
B
_T
B
B
"
"
T
SIG
M
OP
(
(
_ COM
B " +5 V
.
UP
COM
DOWN )
)
DC
" B " PRESSURE
T RANSDUCER
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
" B " REED
SWI T CH
" B " LINEAR
SENSOR
Schematics
3A0870G 57
Schematics
58 3A0870G
Technical Data
Technical Data
Maximum fluid working pressure . . . . . . . . . . . . . . . . . .
See
Hazardous Location Models , page 4.
Maximum working air pressure . . . . . . . . . . . . . . . . . . .
100 psi (0.7 MPa, 7 bar)
Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75 - 100 psi (0.5 - 0.7 MPa, 5.2 - 7 bar)
Air filter inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3/8 npt(f)
Air filtration for air logic (Graco-supplied). . . . . . . . . . . .‘ 5 micron (minimum) filtration required; clean and dry air
Air filtration for atomizing air (user-supplied) 30 micron (minimum) filtration required; clean and dry air
Mixing ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.1:1- 30:1
On-ratio accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
up to + 1%, user selectable
Fluids handled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
one or two component:
• solvent and waterborne paints
• polyurethanes
• epoxies
• acid catalyzed varnishes
• moisture sensitive isocyanates
Viscosity range of fluid. . . . . . . . . . . . . . . . . . . . . . . . . .
20- 5000 cps
Fluid filtration (user-supplied) . . . . . . . . . . . . . . . . . . . .
100 mesh minimum
Fluid flow rate range
G3000, G250 Meter . . . . . . . . . . . . . . . . . . . . . . . . .
G3000HR, G250HR Meter . . . . . . . . . . . . . . . . . . . .
Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . .
75 - 3800 cc/min. (0.02-1.00 gal./min.)
38 - 1900 cc/min. (0.01-0.50 gal./min.)
20 - 3800 cc/min. (0.005-1.00 gal./min.)
38 - 1900 cc/min. (0.01-0.50 gal./min.)
Fluid inlet sizes
Flow Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dose Valve/Color Valve Adapters . . . . . . . . . . . . . . .
1/4 npt(f)
1/4 npt(f)
Fluid outlet size (static mixer) . . . . . . . . . . . . . . . . . . . .. . 1/4 npt(f)
External Power Supply Requirements . . . . . . . . . . . . . .
85 - 250 Vac, 50/60 Hz, 2 amps maximum draw
15 amp maximum circuit breaker required
8 to 14 AWG power supply wire gauge
Operating temperature range . . . . . . . . . . . . . . . . . . . .
41- 122° F (5-50° C)
Approximate Weight
Meter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
200 lb (91 kg)
300 lb (136 kg)
Environmental Conditions Rating . . . . . . . . . . . . . . . . .
indoor use, pollution degree (2), installation category II
Noise Level
Sound pressure level. . . . . . . . . . . . . . . . . . . . . . . . .
Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . .
below 70 dBA below 85 dBA
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
303, 304 SST, Tungsten carbide (with nickel binder), perfluoroelastomer; PTFE
3A0870G 59
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 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 3A0870
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised March 2013
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