Graco 333282E, Color Change and Remote Mix Manifold Kits Instructions

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Instructions/Parts

Color Change and Remote Mix

Manifold Kits

333282E

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 4 for model part numbers and approvals information.

PROVEN QUALITY. LEADING TECHNOLOGY.

2

Contents

Related Manuals ................................................ 3

Models............................................................... 4

Warnings ........................................................... 7

Important Isocyanate (ISO) Information................ 10

Material Self-ignition..................................... 10

Important Acid Catalyst Information ..................... 12

Acid Catalyst Conditions............................... 12

Moisture Sensitivity of Acid Catalysts ............ 13

Setup the Modules.............................................. 14

Setup IS Control Modules............................. 14

Installation.......................................................... 20

Mounting the Control Modules ...................... 20

Air Supply.................................................... 20

Grounding ................................................... 20

Hazardous Location ..................................... 21

Connect the Valve Air Lines.......................... 23

Connect the Air Purge Valve......................... 25

Connect the Fluid Lines................................ 26

Install an Expansion Kit ................................ 33

Troubleshooting.................................................. 36

Color Change Solenoid Valves ..................... 36

Color Change Board .................................... 38

Electrical Schematics.......................................... 40

Standard Models (MC1000, MC2000,

MC3000, MC4000, AC1000,

AC2000) ........................................ 40

Dual Panel Models (MC1002, MC2002,

MC3002, MC4002, AC1002,

AC2002) ........................................ 46

Optional Cables and Modules ....................... 52

Repair................................................................ 53

Replace a Color Valve.................................. 53

Replace a Solenoid ...................................... 54

Replace the Color Change Board Fuse ........... 54

Replace the Color Change Board.................. 55

Parts.................................................................. 56

IS Color Change Kits.................................... 56

Valve Manifold Kits ...................................... 61

Color Change Control Module Kits ................ 72

Expansion Kits............................................. 75

Air/Solvent Chop Expansion Kits................... 76

Hose Selection ............................................ 77

Dimensions ........................................................ 79

Technical Data ................................................... 82

Graco Standard Warranty.................................... 84

333282E

Related Manuals

Related Manuals

Current manuals are available at www.graco.com.

Manual No.

332458

332564

332709

332339

332454

332455

332456

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

Pump Repair-Parts Manual

Color Change Valve Repair-Parts

Manual

Color Change Kits (Non-IS)

Instructions-Parts Manual

3rd and 4th Pump Kits

Instructions-Parts Manual

Manual No.

Description

3A2800 PD2K Electronic Proportioner,

Manual System, Repair-Parts

Manual

332457

332562

3A4186

3A4486

PD2K Electronic Proportioner,

Manual System, Installation

Manual

PD2K Electronic Proportioner,

Manual System, Operation Manual

PD2K Dual Fluid Panel Electronic

Proportioner, Manual System,

Operation Manual

PD2K Dual Fluid Panel Electronic

Proportioner, Auto System,

Operation Manual

333282E 3

4

Models

Models

Intrinsically Safe Modules

These kits utilize intrinsically safe control modules that are installed in the hazardous area, near the dispense valve. See the kit identification label for the product part number. See the module identification label for maximum air working pressure, approval information and certification.

Intrinsically Safe Color Change Module Identification Label Kit Identification Label

0359

II 2 G

Table 1 . Low Pressure, Non-Circulating Remote Mix Manifold Kits

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

Number of Color +

Solvent Valves

1

Number of Catalyst + Solvent Valves

1

24Y962

2 4

2

4

6

8

12

24Y963

24Y964

24Y965

24Y966

26A060

24Y972

24Y973

24Y974

24Y975

26A061

24Y980

24Y981

24Y982

26A062

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

333282E

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

24Y967

24Y968

24Y969

24Y970

24Y971

24Y976

24Y977

24Y978

24Y979

2

24Y983

24Y984

24Y985

4

12 25A606 26A063 26A064

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 1 (Acid) ★ 2 4

1

2

4

6

8

12

24V359

24V360

24V361

24V362

24V363

24V364

26A036

26A037

26A038

26A039

26A040

26A041

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.

333282E 5

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 1 (Acid) ★

24V369

24V370

26A042

26A043

24V371

24V372

24V373

26A044

26A045

26A046

24V389

24V390

24V391

24V392

2

24V402

24V403

24V404

4

12 24V374 26A047 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

★ These acid kits are used by both high and low pressure systems.

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 75 .

Non-Instrinsically Safe Modules

See Manual 332455 for parts, setup, installation, and repair.

6 333282E

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 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.

333282E 7

8

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.

333282E

333282E

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.

9

Important Isocyanate (ISO) Information

Important Isocyanate (ISO) Information

Material Self-ignition

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

Isocyanate Conditions

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates

• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.

• Use of isocyanates involves potentially hazardous procedures. Do not spray with the equipment unless you are trained, qualified, and have read and understood the information in this manuals and in the fluid manufacturer’s application instructions and SDS.

• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material. Equipment must be carefully maintained and adjusted according to instructions in the manual.

• To prevent inhalation of isocynate mists, vapors, and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.

• Avoid all skin contact with iscocyanates.

Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.

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.

10 333282E

Important Isocyanate (ISO) Information

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.

333282E 11

Important Acid Catalyst Information

Important Acid Catalyst Information

Some color change and remote mix manifold kits in this manual are designed for acid catalysts (“acid”) currently used in two-component, wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids. More corrosion-resistant wetted materials of construction are required, and must be used without substitution, to withstand the increased corrosive properties of these acids.

Acid Catalyst Conditions

Acid is flammable, and spraying or dispensing acid creates potentially harmful mists, vapors, and atomized particulates. To help prevent fire and explosion and serious injury.

• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to the acid.

• Use only genuine, manufacturer’s recommended acid-compatible parts in the catalyst system (hoses, fittings, etc). A reaction may occur between any substituted parts and the acid.

• To prevent inhalation of acid mists, vapors, and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the acid manufacturer’s SDS.

• Avoid all skin contact with acid. Everyone in the work area must wear chemically impermeable gloves, protective clothing, foot coverings, aprons, and face shields as recommended by the acid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. Wash hands and face before eating or drinking.

• Regularly inspect equipment for potential leaks and remove spills promptly and completely to avoid direct contact or inhalation of the acid and its vapors.

• Keep acid away from heat, sparks, and open flames. Do not smoke in the work area. Eliminate all ignition sources.

• Store acid in the original container in a cool, dry, and well-ventilated area away from direct sunlight and away from other chemicals in accordance with acid manufacturer’s recommendations. To avoid corrosion of containers, do not store acid in substitute containers. Reseal the original container to prevent vapors from contaminating the storage space and surrounding facility.

12 333282E

Moisture Sensitivity of Acid Catalysts

Acid catalysts can be sensitive to atmospheric moisture and other contaminants. It is recommended the catalyst pump and valve seal areas exposed to atmosphere are flooded with ISO oil, TSL, or other compatible material to prevent acid build-up and premature seal damage and failure.

Important Acid Catalyst Information

NOTICE

Acid build-up will damage the valve seals and reduce the performance and life of the catalyst pump. To prevent exposing acid to moisture:

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere.

Never store acids in an open container.

• Keep the catalyst pump and the valve seals filled with the appropriate lubricant. The lubricant creates a barrier between the acid and the atmosphere.

• Use only moisture-proof hoses compatible with acids.

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

333282E 13

Setup the Modules

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.

NOTE: For a system that has more than one color pump but relatively few color change materials, alternate remote valve maps may be enabled that will consolidate thse colors onto a single IS color change board (module 7). (See “Pump Screen 1” in

Operation Manuals 332562 and 332564 for further detail.)

NOTE: For systems using air/solvent chop to purge the spray device, the air valve will use the bottom right solenoid location (see following tables). It is important to note that the color number (valve) that shares the solenoid location with the air valve cannot be supported in this configuration. (See Operation

Manuals 332562 and 332564, and Installation

Manuals 332457 and 332458 for further detail on air/solvent chip for PD2K.)

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.

14 333282E

Setup the Modules

Figure 1 IS Control Module

Standard Map

Solenoid

1

4

5

2

3

8

9

6

7

IS Control Module 7

Valve Solenoid

Color

Solvent

1

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

2

3

4

5

6

7

8

9

Valve

Catalyst

Solvent

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Color 9

Color 10

Color 11

Color 12*

* Air valve location when using air/solvent chop.

Solenoid

3

4

1

2

5

6

7

8

9

IS Control Module 8

Valve Solenoid

Color 13

Color 14

Color 15

Color 16

Color 17

Color 18

Color 19

Color 20

Color 21

3

4

1

2

5

6

7

8

9

Valve

Color 22

Color 23

Color 24

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

333282E 15

Setup the Modules

8

9

6

7

4

5

2

3

Alternate Map 1 (Consolidation of Two Resin Pumps)

Solenoid

1

IS Control Module 7

Valve Solenoid

Color

Solvent

1

Color 1

Color 2

Color 3

Color 4

Color 5

4

5

2

3

Color 6

Color 17

Color 18

8

9

6

7

Valve

Catalyst

Solvent

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Color 19

Color 20

Color 21

Color 22*

Alternate Map 2 (Consolidation of Three Resin

Pumps)

Solenoid

1

4

5

2

3

IS Control Module 7

Valve Solenoid

Color

Solvent

1

Color 1

Color 2

2

3

Color 3

Color 4

4

5

Valve

Catalyst

Solvent

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

8

9

6

7

Color 17

Color 18

Color 19

Color 20

6

7

8

9

Color 25

Color 26

Color 27

Color 28*

* Air valve location when using air/solvent chop.

Solenoid

7

8

5

6

9

3

4

1

2

IS Control Module 8

Valve Solenoid

Color 7

Color 8

Color 9

Color 10

Color 11

Color 12

Color 13

Color 14

Color 15

7

8

5

6

9

3

4

1

2

Valve

Color 16

Color 23

Color 24

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

Solenoid

6

7

4

5

8

9

1

2

3

Color 5

Color 6

Color 7

Color 8

Color 9

Color 10

Color 11

Color 12

Color 13

IS Control Module 8

Valve Solenoid

6

7

4

5

8

9

1

2

3

Valve

Color 14

Color 15

Color 16

Color 21

Color 22

Color 23

Color 24

Color 29

Color 30

16 333282E

Setup the Modules

NOTE: For a system that uses a mix-at-wall manifold and also has more than one gun, additional remote solvent valves are required, so the IS color change control modules will have modified valve maps.

Similarly, alternate remote valve maps may be enabled to consolidate gun solvent valves and colors from multiple resin pumps onto a single IS color change board (module 7). (See Operation Manuals

332562 and 332564 for further detail on using multiple guns.)

NOTE: For systems using air/solvent chop to purge, each spray device must have its own air valve

(denoted in the tables below). It is important to note that the color numbers (valves) that share the solenoid location with the air valve(s) cannot be supported in this configuration. (See Operation

Manuals 332562 and 332564, and Installation

Manuals 332457 and 332458 for further detail on air/solvent chip for PD2K.)

4

5

2

3

6

7

Standard Map — Multiple Guns

Solenoid

1

IS Control Module 7

Valve Solenoid

Color

Solvent

(Gun 1)

1

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

2

3

4

5

6

7

Valve

Catalyst

Solvent

(Gun 1)

Catalyst 1*

Catalyst 2*

Catalyst 3*

Catalyst 4*

Color 9

Color 10

8 Color 7 8 Color 11

9 Color 8 9 Color 12 /

Air (Gun 1)

* The remote catalyst valve assignment requires special attention when common catalyst materials are used. See “Multiple Guns” in Operation Manuals

332562 or 332564.

8

9

4

5

2

3

6

7

Solenoid

1

IS Control Module 8

Valve Solenoid

Color

Solvent

(Gun 2)

1

Color 13

Color 14

2

3

Color 17

Color 18

4

5

Color 19

Color 20

6

7

Color 21

Color

Solvent

(Gun 3)

8

9

Valve

Catalyst

Solvent

(Gun 2)

Color 22

Color 23

Color 24

Color 25

Color 26

Color 27 /

Air (Gun 2)

Color 28 /

Air (Gun 3)

Catalyst

Solvent

(Gun 3)

333282E 17

Setup the Modules

Alternate Map 1 — Multiple Guns (Consolidation of

Two Guns)

Solenoid

1

2

5

6

3

4

IS Control Module 7

Valve Solenoid

Color

Solvent

(Gun 1)

Color

Solvent

(Gun 2)

Color 1

Color 2

Color 3

Color 4

1

2

3

4

5

6

Valve

Catalyst

Solvent

(Gun 1)

Catalyst

Solvent

(Gun 2)

Catalyst 1*

Catalyst 2*

Catalyst 3*

Catalyst 4*

7

8

Color 5 /

Air (Gun 1)

Color 17

7

8

Color 19

Color 20

9 Color 18 9 Color 21 /

Air (Gun 2)

Alternate Map 2 — Multiple Guns (Consolidation of

Three Guns)

4

5

6

Solenoid

1

2

3

IS Control Module 7

Valve Solenoid

1 Color

Solvent

(Gun 1)

Color

Solvent

(Gun 2)

2

3 Color

Solvent

(Gun 3)

Color 1

Color 2

Color 3/ Air

(Gun 1)

4

5

6

7

8

Color 17

Color 18

7

8

Color 25

Color 26

9 Color 19 /

Air (Gun 2)

9 Color 27 /

Air (Gun 3)

* The remote catalyst valve assignment requires special attention when common catalyst materials are used. See “Multiple Guns” in Operation Manuals

332562 or 332564.

Valve

Catalyst

Solvent

(Gun 1)

Catalyst

Solvent

(Gun 2)

Catalyst

Solvent

(Gun 3)

Catalyst 1*

Catalyst 2*

Catalyst 3*

18

1

2

3

5

6

3

4

7

8

9

7

8

9

4

5

6

Solenoid

1

2

IS Control Module 8

Valve Solenoid

1 Color

Solvent

(Gun 3)

Color 6 2

Valve

Catalyst

Solvent

(Gun 3)

Color 14

Color 7

Color 8

Color 9

Color 10

Color 11

Color 12

Color 13

5

6

3

4

7

8

9

Solenoid

IS Control Module 8

Valve Solenoid Valve

Color 4

Color 5

Color 6

1

2

3

Color 7

Color 8

Color 9

Color 10

Color 11

Color 12

7

8

9

4

5

6

Color 22

Color 23

Color 24

Color 25

Color 26

Color 27

Color 28 /

Air (Gun 3)

Catalyst 4*

Color 13

Color 14

Color 20

Color 21

Color 22

Color 23

Color 24

Color 28

333282E

Setup the Modules

NOTE: The PD2K Dual Panel system supports up to 16 materials per Mix Unit. The maximum number of catalysts per Mix unit is four, but each catalyst reduces the maximum number of colors.

Standard Map — PD2K Dual Panel

Solenoid

1

2

IS Control Module 7

Valve Solenoid

1 Color

Solvent

(Gun 1)

Color 1 2

3

4

5

8

9

6

7

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

3

4

5

6

7

8

9

Valve

Catalyst

Solvent

(Gun 1)

Catalyst 1 /

Color 16

Catalyst 2 /

Color 15

Catalyst 3 /

Color 14

Catalyst 4

/ Color 13 /

Air Purge 1

Color 12

Color 11

Color 10

Color 9

8

9

6

7

4

5

2

3

Solenoid

1

IS Control Module 8

Valve Solenoid

1 Color

Solvent

(Gun 2)

Color 17 2

Color 18

Color 19

Color 20

3

4

5

Color 21

Color 22

Color 23

Color 24

6

7

8

9

Valve

Catalyst

Solvent

(Gun 2)

Catalyst 5 /

Color 32

Catalyst 6 /

Color 31

Catalyst 7 /

Color 30

Catalyst 8

/ Color 29 /

Air Purge 2

Color 28

Color 27

Color 26

Color 25

333282E 19

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.

equipment, fluid, hoses, and stress cause during operation.

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

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 79 .

2. Ensure that the wall and mounting hardware are strong enough to support the weight of the

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.

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

20 333282E

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 72

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 52

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 20 .

Figure 2 Intrinsically Safe Cable Connections

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

Figure 3 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 40

.

333282E 21

Installation

Figure 4 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 20 . 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 79

. 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 23

.

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

Connect the Fluid Lines, page 26 .

22 333282E

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 79 . 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

.

Installation

Connect the Valve Air Lines

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 14

.

The figure on the following page is an example of possible air line configurations.

333282E 23

Installation

24

Example: Air Plumbing for Remote Color Stack

333282E

Installation

Connect the Air Purge Valve

1. Install check valve (CV) at the outlet of the air regulator (AR), then connect tube fitting (F) to the inlet of the check valve.

2. Connect coupler (C) to the inlet of the air purge valve fitting at the manifold. Connect check valve

(CV) to the coupler, then connect tube fitting (F) at the outlet of the check valve.

3. Install the bleed-type air shutoff valve (BV) to the inlet of the air regulator, using nipple (N).

4. Connect the air tube (AT) between the two fittings

(F) and attach the Caution tag.

NOTICE

Use a separate purge air supply line for the air purge valve (APV). Do not connect the air purge valve to the unit’s main air supply or to the air manifold, to avoid contaminating the solenoids, air logic lines, or unit’s main air supply with fluid if the air purge valve (APV) and check valve (CV) fail.

Do not shorten the 25 ft (7.6 m) 1/4 in. (6 mm) OD purge air tubing (AT). Check daily for any visible solvent accumulation. Notify your supervisor if solvent is present.

Install a bleed-type air shutoff valve here.

Purge air line (AT) must be a separate air supply, connected to the check valve (CV).

Do not connect the purge air line to the unit’s main air supply or to the air manifold.

333282E 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.

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 333282E

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 5 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

The figures on the following pages are examples of possible fluid line configurations.

333282E 27

Installation

28

Example: Fluid Connections for Remote Manifold without Circulation

333282E

Installation

333282E

Example: Fluid Connections for Remote Manifold System with Multiple Guns

29

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.

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 6 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

30 333282E

Installation

KEY

A

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

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

The figure on the following page is an example of possible fluid line configurations for a circulation system.

333282E 31

Installation

32

Example: Fluid Connections for Remote Manifold with Circulation

333282E

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 75

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 14 . 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 40

.

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 53 .

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 53 . 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 53 .

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.

333282E 33

Installation

Figure 7 Install an Expansion Kit (Low Pressure

Valve Manifold Shown)

34 333282E

Notes

Installation

333282E 35

Troubleshooting

Troubleshooting

NOTE: Check all possible remedies before disassembling the system.

Color Change Solenoid Valves

All color change solenoid valves may be exercised individually for diagnostic purposes through the Advanced

Display Module (ADM). See “Maintenance Screen 5” in Operations Manuals 332562, 332564, 3A4186, or 3A4486.

NOTE: Refer to

Electrical Schematics, page 40 . 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 38 . If lit,

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

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

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

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

Test the valves as explained under Maintenance Screen 5 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.

36 333282E

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 54

.

• 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.

333282E 37

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 8 Color Change Board

38 333282E

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.

333282E 39

Electrical Schematics

Electrical Schematics

Standard Models (MC1000, MC2000, MC3000, MC4000, AC1000, AC2000)

NOTE: The electrical schematic illustrates all possible wiring expansions in a standard model ProMix PD2K system. Some components shown are not included with all systems.

NOTE: See

Optional Cables and Modules, page 52

, for a list of cable options.

FAN

(24P658)

(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)

(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 9 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)

GUN TRIGGER INPUTS

119159

119159

119159

119159

2

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)

40 333282E

Electrical Schematics

SPLITTER

(16P243)

5 4 3 2 1

UNUSED UNUSED UNUSED

CONTINUED ON PAGE 3 CONTINUED ON PAGE 3

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

UNUSED

CABLE (16T280)

1 2 3

UNUSED UNUSED

BARRIER

BOARD

(248192)

3

CABLE (121227)

2

3 P3 P4

AWI

GATEWAY

(24R910)

5

CABLE

(121227)

3

2

3 P3

SOLVENT CUTOFF (121324)

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN SOLVENT

METER

(258718)

P4

INTEGRATION

GATEWAY

5

UNUSED

UNUSED

10

UNUSED

CABLE

(121001)

3

+24VDC

COM

UNUSED

UNUSED

+24VDC

COM

+24VDC

COM

UNUSED

8

GCA MODULE

EFCM

(24N913)

1

2

6

7

4

5

8

9

10

12

5

1 2 3 4 5 6 7 8 9 10

1

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

2

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, 24T799)

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

BREAKOUT MODULE PUMP 1 (24N527)

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

1

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

BREAKOUT MODULE PUMP 2 (24N527)

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

1

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 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

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

TWISTED PAIR CABLE (16W159)

DETAIL B, HIGH PRESSURE PUMPS

(24M707, 24M715, 24T800)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P685) DRAIN/FOIL

MOTOR

GROUND

SCREW

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 10 Electrical Schematic, Sheet 2, Part 1

CONTINUED ON THE NEXT PAGE

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)

10

333282E 41

Electrical Schematics

GUN TRIGGER INPUTS

GCA MODULE

EFCM

(24N913)

1 2 3 4 5 6 7 8

3

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

4

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

9

6

11

12

8

9

3

4

2

1

5

6

7

11

12

8

9

3

4

2

1

5

6

3

4

1

2

5

SIG

COM

SIG

COM

SIG

COM

COM

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

3

4

2

1

5

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 11 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)

42 333282E

Electrical Schematics

FROM CAN IS BOARD (24M485)

2

CABLE (15V206)

FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

MANIFOLD

DUMP

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+12VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

4

3

6

5

2

1

1 2 3 4 5

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP*

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

2

CABLE (15V206)

Figure 12 Electrical Schematic, Sheet 3

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

333282E 43

Electrical Schematics

FLUSH

CATALYST 3

CATALYST 4

MANIFOLD

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

5

6

2

3 J8

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J9

6

5

6

2

3 J15 J16

3

2

5

4

1

3

2

5

4

1

5

6

2

3 J14 J10

1 2 3 4 5

3

2

5

4

1

COM

+24VDC

+24VDC

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 3

CATALYST 4

UNUSED

UNUSED

UNUSED

UNUSED

FLUSH

CATALYST 1

CATALYST 2

MANIFOLD

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

4

5

6

1

2

J8

5 4 3 2

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

1

J9 4

3

6

5

6

4

5

6

1

2

J15 J16 4

3

6

5

4

5

6

1

2

J14

1 2 3 4 5

J10

4

3

6

5

+24VDC

COM

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

ALTERNATE CONFIGURATION

FOR CATALYST CHANGE CONTROL

Figure 13 Electrical Schematic, Sheet 3, Alternate

Configuration for Catalyst Change Control

CONTINUED ON THE NEXT PAGE

44 333282E

Electrical Schematics

FROM CAN IS BOARD (24M485)

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

COM

+12VDC

COM

+12VDC

COM

COM

+12VDC

COM

+12VDC

COM

COM

+12VDC

COM

3

4

1

2

5

6

4

5

6

1

2

1 2 3 4 5

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8 J9

4

3

6

5

2

1

7

J15 J16

3

2

5

4

1

3

4

1

2

5

6

J14 J10

4

3

6

5

2

1

1 2 3 4 5

+12VDC

COM

+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

+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 8

(COLORS

41 THRU 48)

J8 J9

7

3

4

1

2

5

6

J15 J16

4

3

6

5

2

1

4

3

6

5

4

5

6

1

2

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

+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 14 Electrical Schematic, Sheet 3, Hazardous

Location

333282E 45

Electrical Schematics

Dual Panel Models (MC1002, MC2002, MC3002, MC4002, AC1002, AC2002)

NOTE:The electrical schematic illustrates all possible wiring expansions in a dual panel model ProMix

PD2K system. Some components shown are not included with all systems.

NOTE: See

Optional Cables and Modules, page 52

for a list of cable options.

POWER MODULE

(26A189)

2 CABLE

(15V206)

2

CABLE

(15V206)

2 POSITION

SWITCH

(16U725)

CABLE

16T658

LINE FILTER

(16V446)

CABLE

16H078

TERMINAL BLOCK

(114095)

POWER IN

24V

POWER

SUPPLY

(16T660)

48V-10A POWER SUPPLY

(16U820)

RELAY 1 RELAY 2

TERMINAL BLOCK WITH FUSES

INTEGRATION

GATEWAY

5

CABLE (121227)

AWI

GATEWAY

(24R910)

5

CABLE (121001)

MODULE 1 (24N935)

2

CABLE

(15V206)

MODULE 2 (24N935) MODULE 3 (24N935)

2

CABLE

(15V206)

MODULE 4 (24N935) MODULE 5 (24N935)

2

CABLE

(15V206)

MODULE 6 (24N935)

FAN

(24P658)

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

CABLE 126232

OR 17N315

SOLENOID (16P812)

UP

DOWN

SOLVENT

METER 1

(258718)

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

CABLE 126232

OR 17N315

SOLENOID (16P812)

UP

DOWN

SOLVENT

METER 2

(258718)

SPLITTER

(16P243)

CABLE (121227)

16T072

CAN

IS BOARD

(24M485)

17L058

CABLE (16T280)

BARRIER

BOARD

(248192)

GCA

MODULE

EFCM

(24N913)

CABLE

15V819

AIR FLOW SW. 1 (119159)

AIR FLOW SW. 2 (119159)

GFB PRESS. SW. 1 (121323)

GFB PRESS. SW. 2 (121323)

GFB VALVE 1 (121324)

GFB VALVE 2 (121324)

AIR

CONTROL

MODULE

(26A231)

SOLVENT CUTOFF VALVE (121324)

SOLVENT CUTOFF VALVE (121324)

SWITCH (120278)

SWITCH (120278)

SWITCH (120278)

SWITCH (120278)

SOLVENT

FLOW

INPUTS

SAFETY INTERLOCK SWITCH

CABLE

(121003)

3

ADVANCED DISPLAY MODULE

(24E451)

LIGHT

TOWER

(15X472)

COLOR CHANGE

MODULE 7

(24R219)

7

1

CABLE

(16V426)

BOOTH CONTROL

(24M731)

WITH SHUNT

(17M540)

4

CABLE (16T659)

COLOR CHANGE

MODULE 8

(24R219)

7

1

CABLE

(16V426)

BOOTH

CONTROL

(24M731) FAN

(24P658)

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

FAN

(24P658)

(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

1 CABLE (16V429)

HAZARDOUS LOCATION

NON-HAZARDOUS LOCATION

46 333282E

Electrical Schematics

SPLITTER

(16P243)

5 4 3 2 1

UNUSED UNUSED UNUSED

24V

POWER

SUPPLY

(16T660)

3

CABLE (121227)

3

4

1

2

5

3

4

1

2

5

CABLE (15V206)

16T072

1 2 3 4 5

2

4

1 2 3 4 5

CAN IS BOARD

1 2 3 4 5

1

(NON IS)

(IS)

(24M485)

3

1 2 3 4 5

SPLITTER (17L058)

CABLE (16T280)

UNUSED UNUSED

UNUSED J4

1 2 3

J5

BARRIER

BOARD

(248192)

P3 P4

AWI

GATEWAY

(24R910)

5

4

5

CABLE

(121227)

3

UNUSED

UNUSED

P3 P4

INTEGRATION

GATEWAY

5

UNUSED

CABLE

(121001)

3

3

1

10

8

SOLVENT CUTOFF VALVE 1 (121324)

SOLVENT CUTOFF VALVE 2 (121324)

GFB OUTPUT VALVE 1

GFB OUTPUT VALVE 2

GREEN/BLACK

ORANGE/BLACK

BLUE/BLACK

RED/WHITE

SAFETY INTERLOCK SWITCH

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

SIG

COM

UNUSED

8

9

6

7

4

5

2

3

10

11

12

5

4

25 PIN D-SUB

CABLE (16T659)

GROUND

BAR

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

1 2 3 4

7

5 6 7 8

8

1 2 3 4

GCA MODULE

2

EFCM

(24N913)

3 4

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

1 2 3 4

7

5 6 7 8

6

7

8

5

6

3

4

2

1

9

10

11

12

7

7

8

5

6

3

4

2

1

9

10

11

12

9

8

1 2 3 4

L (BROWN) N (BLUE)

N03 N03

2 POSITION

SWITCH

(16U725)

N04 N04

CABLE

(16T658)

L N

LINE

FILTER

(16V446)

L GND N

CABLE

(16H078)

L N GND

TERMINAL

BLOCK

(114095)

L N GND

GRND (GRN/YEL)

N L GRND

48V-10A

POWER SUPPLY

(16U280)

- - + +

15

18

RELAY

2

A1

A2

15

18

RELAY

1

A1

A2

+ - + - + - + -

4 3 2 1

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 1

SEE DETAIL A OR B

BROWN (UNUSED)

DRAIN (UNUSED)

BLUE

BLACK

BROWN (UNUSED)

DRAIN (UNUSED)

BLUE

BLACK

DETAIL A, LOW PRESSURE PUMPS

(24M706, 24M714, 24T799)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P684) DRAIN/FOIL

CABLE (126232 OR 17N315)

PUMP 1

MANIFOLD

SOLVENT

METER 1

(258718)

MAC SERIES 46 (16P812 QTY

GND

SCREW

TWISTED PAIR CABLE (16W159)

+24VDC COM +24VDC COM

DETAIL B, HIGH PRESSURE PUMPS

(24M707, 24M715, 24T800)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P685) DRAIN/FOIL

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 2

SEE DETAIL A OR B

CABLE (126232 OR 17N315)

TWISTED PAIR CABLE (16W159)

+24VDC COM +24VDC COM

PUMP 2

MANIFOLD

SOLVENT

METER 2

(258718)

MAC SERIES 46 (16P812 QTY

GND

SCREW

MOTOR

GROUND

SCREW

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

333282E 47

Electrical Schematics

3

2

5

4

1

3

4

1

2

5

10

8

8

7

6

5

4

3

2

1

9

10

11

12

5

1

GCA MODULE

EFCM

(24N913)

2 3 4

6

8

7

6

5

4

3

2

1

10

9

11

12

SIG

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM

BLACK

WHITE

RED

GREEN

AIR FLOW SWITCH 1

AIR FLOW SWITCH 2

SOLVENT FLOW SW. 1 (120278) LEFT BRKT

SOLVENT FLOW SW. 2 (120278) LEFT BRKT

SOLVENT FLOW SW. 3 (120278) RIGHT BRKT

SOLVENT FLOW SW. 4 (120278) RIGHT BRKT

7

8

7

6

5

4

3

2

1

9

10

11

12

9 3

4

1

2

5

PLC DISCRETE 4-20mA INPUT 1

PLC DISCRETE 4-20mA COMMON 1

PLC DISCRETE 4-20mA INPUT 2

PLC DISCRETE 4-20mA COMMON 2

UNUSED

UNUSED

UNUSED

UNUSED

SIG

COM

SIG

COM

ORANGE

BLUE

WHITE/BLACK

RED/BLACK

CABLE

(121003)

3

3

4

1

2

5

ADVANCED

DISPLAY MODULE

(24E451)

GFB INPUT PRESSURE SWITCH 1

GFB INPUT PRESSURE SWITCH 2

3

4

2

1

5

LIGHT

TOWER

(15X472)

CABLE

15V819

AIR CONTROL MODULE (26A231)

BLACK

WHITE

RED

GREEN

ORANGE

BLUE

WHITE/BLACK

RED/BLACK

GREEN/BLACK

ORANGE/BLACK

BLUE/BLACK

RED/WHITE

TERMINAL

BLOCKS

7

8

5

6

3

4

1

2

9

10

11

12

+ SIG

- COM

+ SIG

- COM

+ SIG

- COM

+ SIG

- COM

+ 24VDC

- COM

+ 24VDC

- COM

RED

BLACK

RED

BLACK

AIR FLOW SWITCH 1

119159

AIR FLOW SWITCH 2

119159

GFB INPUT PRESSURE SWITCH 1

121323

GFB INPUT PRESSURE SWITCH 2

121323

GFB OUTPUT VALVE 1

121324

GFB OUTPUT VALVE 2

121324

2

1 2 3 4 5

25 PIN D-SUB

CABLE (16T659) 4

3

1 2 3 4

1

4

1 2 3 4 5

BREAKOUT MODULE PUMP 3 (24N527)

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

2

1 2 3 4 5

3

1 2 3 4

1

4

1 2 3 4 5

BREAKOUT MODULE PUMP 4 (24N527)

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

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 4

SEE DETAIL A OR B

+24VDC COM +24VDC COM

PUMP 3

MANIFOLD

G3000

METER

PUMP 3

258718,16M510,

OR 16M519)

MAC SERIES 46 (16P812 QTY

+24VDC COM +24VDC COM

PUMP 4

MANIFOLD

G3000

METER

PUMP 4

258718,16M510,

OR 16M519)

MAC SERIES 46 (16P812 QTY

GND

SCREW

Figure 17 Electrical Schematic, Sheet 2, Part 2

CONTINUED ON THE NEXT PAGE

TWISTED PAIR CABLE (16W159)

TWISTED PAIR CABLE (16W159)

48 333282E

Electrical Schematics

FROM CAN IS BOARD (24M485)

2 CABLE (15V206)

FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

MANIFOLD

DUMP

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+12VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP*

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

Figure 18 Electrical Schematic, Sheet 3, Part 1

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

2

CABLE (15V206)

333282E 49

Electrical Schematics

FROM CAN IS BOARD (24M485)

1 CABLE (16V429)

NON-HAZARDOUS LOCATION

HAZARDOUS LOCATION

COLOR FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

4

3

2

1

6

5

4

3

2

1

6

5

1 2 3 4 5

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8 J9

3

4

5

6

1

2

7

J15 J16

3

4

5

6

1

2

4

3

2

1

6

5

J14 J10

5 4 3 2 1

3

4

5

6

1

2

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

MANIFOLD

CATALYST FLUSH

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

COLOR 9

COLOR 10

COLOR 11

COLOR 12

5 4 3 2 1

BOOTH CONTROL

(24M731)

WITH SHUNT

(17M540)

1 2 3 4 5

J1

COLOR 13

COLOR 14

COLOR 15

COLOR 16

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

MANIFOLD

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

4

3

2

1

6

5

1 2 3 4 5

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

J8 J9

7

4

3

2

1

6

5

J15 J16

3

4

5

6

1

2

3

4

5

6

1

2

4

3

2

1

6

5

J14

5 4 3 2

J10

3

4

5

6

1

2

1

5 4 3 2 1

BOOTH CONTROL

(24M731)

Figure 19 Electrical Schematic, Sheet 3, Part 2

CONTINUED ON THE NEXT PAGE

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

MANIFOLD

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

50 333282E

Electrical Schematics

FLUSH

CATALYST 3

CATALYST 4

MANIFOLD

COM

+24VDC

COM

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J8

3

4

1

2

5

6

J15

6

J9

J16

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

3

1

5

4

3

1

5

4

+24VDC

COM

+24VDC

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 3

CATALYST 4

FLUSH

CATALYST 1

CATALYST 2

MANIFOLD

COM

+24VDC

COM

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

5

6

5 4 3 2

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

1

J8 J9

3

1

5

4

6

3

4

1

2

5

6

J15 J16

3

1

5

4

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

+24VDC

COM

+24VDC

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

ALTERNATE CONFIGURATION

FOR CATALYST CHANGE CONTROL

IN NON-HAZARDOUS LOCATION

Figure 20 Electrical Schematic, Sheet 4, Alternate

Configuration for Catalyst Change Control

333282E 51

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 40

.

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)

Communication Module for integration with a PLC, Non-Hazardous Locations Only

Module Part No.

Module Part No.

CGMDN0*, DeviceNet CGMPN0*, Profinet

CGMEP0*, Ethernet IP 24W462*, Modbus TCP

* You must purchase CGM Installation Kit 24W829 for use with these devices.

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

52 333282E

Repair

Repair

3. Using the other end of the tool (114), screw it onto the valve (3). Leave a gap to allow the tool handle (114a) to be inserted in step 4, below.

• 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 22 Attach Tool to the Valve

4. Use the tool handle (114a) to pull valve (3) 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 23 Remove the Valve

NOTE: See manual 332454 to repair the valve.

5. 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.

6. Return the system to service.

Figure 21 Remove Retainer

333282E 53

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 40

.

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 40

.

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.

54 333282E

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 jam nuts (336) from the two connectors.

5. Turn three screws (334) to loosen or remove ground plate (333).

6. Remove mounting screws (303).

7. Slide board (302) out from underneath ground plate tabs.

8. Install the new board under the ground plate tabs. Make sure fuse holder (308) is between the board and the bracket tabs. Reinstall mounting screws (303).

NOTE: If bracket (333) was removed, ensure the nylon non-conductive plate (332) is re-installed between enclosure and bracket.

9. Turn three screws (334) to install or tighten ground plate (333).

10. Install and tighten jam nuts (336) onto the two connectors.

11. Reconnect the cables to the proper connectors, as noted in step 3. See

Electrical Schematics, page 40 .

12. Reinstall the cover (304). Restore electrical power to the system.

Figure 24 Control Module Repair (IS Module Shown)

333282E 55

Parts

Parts

IS Color Change Kits

56

Ref.

No.

101

103

104

105

106

107

108

109

110

111

112

113

114

Part No.

24V436

24N346

16W564

16W563

26A079

16Y954

100015

104429

113469

24U236

24R124

24U239

24U240

223547

100016

16V429

115 ● 112497

116 ● 166846

Description Qty

KIT, manifold, valve; . See

Valve Manifold Kits, page

61

for available kits.

MANIFOLD, mix, remote

HOSE, coupled, 2.5 ft.

HOSE, static mixer

Low Pressure

High Pressure

Acid, High Pressure

KIT, module, control

BRACKET, manifold

NUT, hex

SCREW, cap, hex

Low Pressure

High Pressure

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

SWIVEL, union, 3/8 npsm(f) x 1/4 npt(m)

FITTING, adapter, 1/4 npt(m) x 1/4 npsm(m)

2

1

2

1

4

4

1

2

1

1

2

4

1

1

1

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

● Used only with high pressure acid kits. The acid static mixer does not have a 3/8 npsm fitting, so this swivel and adapter are needed.

333282E

Remote Mix Manifold

Parts

7

8

5

6

9

2

3

4

10

11

12

Ref.

No.

1

16Y952

111603

16Y951

16W572

16U403

24T894

16Y953

17A612

Part No.

Description

16Y950

070303

070408

116343

MANIFOLD, mix, color/catalyst

TUBE, integrator

O-RING; ptfe

FITTING, outlet

O-RING; ptfe

PLUG, dose pump

VALVE, check; 316 sst

BRACKET

SCREW, cap, socket head;

10–24 x 0.5 in. (13 mm), sst

LUBRICANT, grease

SEALANT, pipe; sst

SCREW, ground

Qty

1

1

1

1

2

1

1

1

4

1

1

1

333282E

Ref.

No.

13

14

Part No.

223547

070494

Description

WIRE ASSEMBLY; 25 feet

(7.6 m)

ADHESIVE, anerobic

1 Apply lubricant (10) to all seals.

2 Apply sealant (11) to all pipe threads.

Install check valve (7) with flow arrow to direction shown.

4 Items not shown (10), (11), (13), (14).

Apply adhesive (14) to threads.

Qty

1

1

Torque to 25 ft-lbs (34 N·m).

Bolts not supplied, will vary depending on installation

57

Parts

24Y967

24Y968

24Y969

24Y970

24Y971

24A606

24Y976

24Y977

24Y978

24Y979

26A063

24Y983

24Y984

24Y985

26A064

24Y962

24Y963

24Y964

24Y965

24Y966

26A060

24Y972

24Y973

24Y974

24Y975

26A061

24Y980

24Y981

24Y982

26A062

Low Pressure IS Kits

Kit No.

Kit Description Standard Valve Manifold Kits (101) [see

High Pressure Valve

Manifold Kits, page 66

for all available kits]

Low Pressure Non-Circulating Color Change Kits

1 color and 1 catalyst 24Y936 (2)

2 colors and 1 catalyst

4 colors and 1 catalyst

6 colors and 1 catalyst

8 colors and 1 catalyst

24Y938, 24Y936

24Y942, 24Y936

24Y946, 24Y936

24Y950, 24Y936

12 colors and 1 catalyst 24Y936, 26A286

2 colors and 2 catalysts 24Y938 (2)

4 colors and 2 catalysts

6 colors and 2 catalysts

24Y942, 24Y938

24Y946, 24Y938

8 colors and 2 catalysts 24Y950, 24Y938

12 colors and 2 catalysts 24Y938, 26A286

4 colors and 4 catalysts

6 colors and 4 catalysts

24Y942 (2)

24Y946, 24Y942

8 colors and 4 catalysts 24Y950, 24Y942

12 colors and 4 catalysts 24Y942, 26A286

Low Pressure Circulating Color Change Kits

1 color and 1 catalyst 24Y937, 24Y936

2 colors and 1 catalyst

4 colors and 1 catalyst

6 colors and 1 catalyst

24Y939, 24Y936

24Y943, 24Y936

24Y947, 24Y936

8 colors and 1 catalyst 24Y951, 24Y936

12 colors and 1 catalyst 25A605, 24Y936

2 colors and 2 catalysts 24Y939, 24Y938

4 colors and 2 catalysts 24Y943, 24Y938

6 colors and 2 catalysts 24Y947, 24Y938

8 colors and 2 catalysts 24Y951, 24Y938

12 colors and 2 catalysts 24Y938, 25A605

4 colors and 4 catalysts 24Y943, 24Y942

6 colors and 4 catalysts 24Y947, 24Y942

8 colors and 4 catalysts 24Y951, 24Y942

12 colors and 4 catalysts 24Y942, 25A605

Control Module

Kit (106) [see

IS Color Change Control

Modules, page 72

for parts]

24T571

24T571

24T572

24T573

24T574

24T774

24T571

24T572

24T573

24T574

24T774

24T775

24T776

24T777

24T778

24T571

24T571

24T572

24T573

24T574

24T774

24T571

24T572

24T573

24T574

24T774

24T775

24T776

24T777

24T778

58 333282E

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

High Pressure Valve

Manifold Kits, page 66

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 72

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

333282E 59

Parts

Acid IS Kits

Acid color change kits are used for high pressure and for low pressure systems.

Kit No.

26A036

26A037

26A038

26A039

26A040

26A041

Kit Description

Acid Non-Circulating Color Change Kits

1 color and 1 catalyst

2 colors and 1 catalyst

4colors and 1 catalyst

6colors and 1 catalyst

Standard Valve Manifold Kits (101) [see

High Pressure Valve

Manifold Kits, page 66

for all available kits]

24T647, 24X360

24T648, 24X360

24T650, 24X360

24T652, 24X360

8colors and 1 catalyst 24T654, 24X360

12 colors and 1 catalyst 24T658, 24X360

Control Module

Kit (106) [see

IS Color Change Control

Modules, page 72

for parts]

24R219

24R219

24R220

24R221

24R222

24V406

26A042

26A043

26A044

26A045

26A046

26A047

Acid Circulating Color Change Kits

1 color and 1 catalyst 24T677, 24X360

2 colors and 1 catalyst

4colors and 1 catalyst

24T678, 24X360

24T680, 24X360

6colors and 1 catalyst

8colors and 1 catalyst

24T682, 24X360

24T684, 24X360

12 colors and 1 catalyst 24T688, 24X360

24R219

24R219

24R220

24R221

24R222

24V406

60 333282E

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

26A274

26A286

26A276

26A278

26A280

26A282

26A284

Kit No.

24Y936

24Y938

24Y940

24Y942

24Y944

24Y946

24Y948

24Y950

24Y952

26A272

A

A

A

A

A

A

A

A

A

Series

A

A

A

A

A

A

A

A

Kit Description

2 valves

3 valves

4 valves

5 valves

6 valves

7 valves

8 valves

9 valves

10 valves

11 valves

12 valves

13 valves

14 valves

15 valves

16 valves

17 valves

18 valves

Circulating Valve Manifold Kits

26A275

25A605

26A277

26A279

26A281

26A283

26A285

Kit No.

24Y937

24Y939

24Y941

24Y943

24Y945

24Y947

24Y949

24Y951

24Y953

26A273

A

A

A

A

A

A

A

A

A

Series

A

A

A

A

A

A

A

A

Kit Description

2 valves

3 valves

4 valves

5 valves

6 valves

7 valves

8 valves

9 valves

10 valves

11 valves

12 valves

13 valves

14 valves

15 valves

16 valves

17 valves

18 valves

333282E 61

Parts

Valve Manifold Kit Parts

Non-Circulating

Kits

Circulating Kits

62 333282E

8

9

10

6

7

4

5

11

1

2

Ref.

No.

3

24R051

16N256

111457

24T521

24T522

157974

104092

100179

Part No.

17J100

124878

24T441

24T442

Description

MANIFOLD, SST

O-RING; FEP encapsulated fluoroelastomer

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

Parts

14

15

16

17

18

19

Ref.

No.

12

13

22

Part No.

104893

24T523

111328

24T525

24T524

111504

557716

104644

24T441

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)

VALVE, solvent, for circulating kits; includes item 2

Qty

1

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

333282E 63

Parts

Kit No.

1

24Y936 1

24Y938 2

24Y940 2

24Y942 3

24Y944 3

24Y946 4

24Y948 4

24Y950 5

24Y952 5

26A272 6

26A274 6

26A286 7

26A276 7

26A278 8

26A280 8

26A282 9

26A284 9

Low Pressure Non-Circulating Valve Manifold Kit Part Quantities

2

2

4

4

6

6

8

3

2

3

4

5

8 8

10 9

6

7

4

0

1

0

1

0

1

0

1

10 10 0

12 11 1

12 12 0

14 13 1

14 14 0

16 15 1

16 16 0

18 17 1

18 18 0

5

2

4

4

6

6

8

6

2

3

3

4

4

5

8 5

10 6

10

12

12

6

7

7

14 8

14 8

16 9 1

16 9 1

18 10 1

18 10 1

1

1

1

1

1

1

1

1

1

1

1

1

7

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

8

1

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

10

3

Reference Numbers

6

7

4

5

12 13 14 15 16

3 3 2 0 3

4

5

3

4

3

3

0

0

6

7

5

8

9

8

9 8

10 10 9

6

7

11 11 10 6

12 12 11 9

13 13 12 9

14 14 13 9

15 15 14 9

3

3

6

6

6

3

3

0

0

3

3

0

0

3

3

16 16 15 12 0

17 17 16 12 0

18 18 17 12 3

19 19 18 12 3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

17 18 19

1 2 0

5

4

2

0

7

6

9

8

2

0

2

0

11 2

10 0

13 2

12 0

15 2

14 0

17 2

16 0

19 2

18 0

64 333282E

Parts

Kit No.

1

24Y937 1

24Y939 2

24Y941 2

24Y943 3

24Y945 3

24Y947 4

24Y949 4

24Y951 5

24Y953 5

26A273 6

26A275 6

26A605 7

26A277 7

26A279 8

26A281 8

26A283 9

26A285 9

Low Pressure Circulating Valve Manifold Kit Part Quantities

Reference Numbers

4

4

2

2

3

1

2

3

4 5

0 2

1 4

0 4

6

2

3

3

6

6

8

8

10 8

6

7

4

5

1

0 6

1 8

0

1

6

8

10

5

6

10 9 0 10 6

12 10 1 12 7

12 11 0 12 7

4

4

5

1

1

1 3

1 1 3

1 1 3

1 1 3

1 3

14 12 1 14 8

14 13 0 14 8

1 1 3

1 1 3

1 1 3

1

1

1 3

1 3

16 14 1 16 9 1 1 3

16 15 0 16 9 1 1 3

18 16 1 18 10 1 1 3

18 17 0 18 10 1 1 3

7 8 10 12 13

1 1 3 4 4

1 1 3

1 1 3

6

8

6

8

10 10 5

11 11 6

14 14 7

16 16 8

18 18 9

3

4

14 15

2 0

3

3

20 20

26 26

28 28

30 30

10

13

14

15

3

3

6

6

6

6

22 22 11 9

24 24 12 9

9

9

12

0

0

16

3

3

3

0

0

3

0

32 32 16 12 0

34 34 17 12 3

36 36 18 12 3

3

0

0

3

3

1 1

1 3

1 1

1 3

1 1

1 3

1 1

1 3

1 1

17 18

1 1

1 3

1 1

1 3

1 1

1 3

1 1

1 3

0 1

2 1

0 1

2 1

0 1

2 1

0 1

2 1

0 1

19 22

0 1

2 1

0 1

2 1

0 1

2 1

0 1

2 1

333282E 65

Parts

High Pressure Valve Manifold Kits

Non-Circulating Valve Manifold Kits

24T656

24T657

24T658

24T659

24T660

24T661

24T662

24T663

24T664

Kit No.

24T647

24T648

24T649

24T650

24T651

24T652

24T653

24T654

24T655

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

Series

A

A

11 valves

12 valves

13 valves

14 valves

15 valves

16 valves

17 valves

18 valves

19 valves

Kit Description

2 valves

3 valves

4 valves

5 valves

6 valves

7 valves

8 valves

9 valves

10 valves

Kit No.

24T665

24T666

24T667

24T668

24T669

24T670

24T671

24T672

24T673

24T674

24T675

24T676

24X360 (acidcatalyzed)

24T845 (acidcatalyzed)

24T846 (acidcatalyzed)

A

A

A

A

A

A

A

A

A

A

A

A

A

A

Series

A

Kit Description

20 valves

21 valves

22 valves

23 valves

24 valves

25 valves

26 valves

27 valves

28 valves

29 valves

30 valves

31 valves

2 valves

3 valves

5 valves

66 333282E

Circulating Valve Manifold Kits

Kit No.

24T677

24T678

24T679

24T680

24T681

24T682

24T683

24T684

24T685

24T686

24T687

24T688

24T689

24T690

24T691

A

A

A

A

A

A

A

Series

A

A

A

A

A

A

A

A

Kit Description

2 valves

3 valves

4 valves

5 valves

6 valves

7 valves

8 valves

9 valves

10 valves

11 valves

12 valves

13 valves

14 valves

15 valves

16 valves

Kit No.

24T692

24T693

24T694

24T695

24T696

24T697

24T698

24T699

24T700

24T701

24T702

24T703

24T704

24T705

24T706

A

A

A

A

A

A

A

A

Series

A

A

A

A

A

A

A

Parts

Kit Description

17 valves

18 valves

19 valves

20 valves

21 valves

22 valves

23 valves

24 valves

25 valves

26 valves

27 valves

28 valves

29 valves

30 valves

31 valves

333282E 67

Parts

Valve Manifold Kit Parts

Non-Circulating

Kits

Circulating Kits

68 333282E

7

8

10

4

5

6

12

Ref.

No.

1

2

3

Part No.

16N271

124878

24T581

24T582

24R052

16N269

111457

24T725

24T726

111820

104893

Description

MANIFOLD, for circulating kits

O-RING; FEP encapsulated fluoroelastomer

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

SCREW, cap, socket head;

10–24 x 0.75 in. (19 mm)

O-RING; ptfe

Qty

Parts

Ref.

No.

13

14

15

16

18

19

22

Part No.

24T523

111328

24T729

24T728

557716

104644

24T581

24T583

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)

VALVE, solvent, for circulating kits; includes item 2

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

Qty

1

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

333282E 69

Parts

24T660

24T661

24T662

24T663

24T664

24T665

24T666

24T667

24T668

24T669

24T647

24T648

24T649

24T650

24T651

24T652

24T653

24T654

24T655

24T656

24T657

24T658

24T659

24T670

24T671

24T672

24T673

24T674

24T675

24T676

24X360

24U182

24U183

3

3

4

4

5

2

2

1

1

4

4

2

2

6

6

8

8 8

10 9

5

6

7

3

4

3

2

5

6

6

7

7

10 10 0

12 11 1

12 12 0

14 13 1

14 14 0

8

8

9

16 15 1

16 16 0

18 17 1

9 18 18 0

10 20 19 1

1

0

1

0

1

1

0

4

0

10 20 20 0

11 22 21 1

11 22 22 0

12 24 23 1

12 24 24 0

13 26 25 1

13 26 26 0

14 28 27 1

14 28 28 0

15 30 29 1

2

3

15 30 30 0

16 32 31 1

1 1 1 0

4

6

3

5

1

1

High Pressure Non-Circulating Valve Manifold Kit Part Quantities

Kit No.

4

4

5

2

3

3

6

2

6

6

8

4

4

5

8 5

10 6

10

12

12

6

7

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

7

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

4

6

30 16 1

32 17 1

2 2 1

3

4

1

1

Reference Numbers

4

5

12

3

13

3

4

5

14

2

3

4

6

7

6

7

5

8

9

8

9 8

10 10 9

6

7

11 11 10 6

12 12 11 9

13 13 12 9

14 14 13 9

15 15 14 9

3

3

6

6

6

3

3

15 16

0 3

0

0

3

3

0

0

3

3

0

0

3

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

22 22 21 15 3

23 23 22 15 3

24 24 23 18 0

25 25 24 18 0

26 26 25 18 3

27 27 26 18 3

28 28 27 21 0

29 29 28 21 0

30 30 29 21 3

4

6

31 31 30 21 3

32 32 31 24 0

3 3 2 0 3

4

6

3

5

3

3

0

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

1

1

1

8

1

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

3

3

3

10

3

20 0

23 2

22 0

25 2

24 0

27 2

26 0

29 2

28 0

31 2

5

7

30 0

33 2

2 0

2

2

10 0

13 2

12 0

15 2

14 0

13 2

16 0

19 2

18 0

21 2

5

4

18

2

7

6

9

8 0

11 2

2

0

2

2

0

19

0

70 333282E

Parts

High Pressure Circulating Valve Manifold Kit Part Quantities

Kit No.

1

24T677 1

24T678 2

24T679 2

24T680 3

24T681 3

24T682 4

24T683

24T684

4

5

24T685 5

24T686 6

24T687 6

24T688 7

24T689 7

2

2

4

3

1

2

4

0

1

4

6

3

6

8

8

10 8

6

7

4

5

10 9 0

12 10 1

12 11 0

14 12 1

14 13 0

0

1

0

1

0

1

24T690 8

24T691 8

24T692 9

16 14 1

16 15 0

18 16 1

24T693 9 18 17 0

24T694 10 20 18 1

24T695 10 20 19 0

24T696 11 22 20 1

24T697 11 22 21 0

24T698 12 24 22 1

24T699 12 24 23 0

24T700 13 26 24 1

24T701 13 26 25 0

24T702 14 28 26 1

24T703 14 28 27 0

24T704 15 30 28 1

24T705 15 30 29 0

24T706 16 32 30 1

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

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

Reference Numbers

8 10 12 13 14 15

1 3 4 4 2 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

6 6 3 3 0

8

10

12

14

8

10

12

14

4

5

6

7

3

16 16 8

18 18 9

20 20 10 6

22 22 11 9

24 24 12 9

26 26 13 9

28 28 14 9

3

3

6

6

6

30 30 15 12 0

32 32 16 12 0

34 34 17 12 3

36 36 18 12 3

38 38 19 15 0

3

0

0

0

3

3

3

0

3

3

0

40 40 20 15 0

42 42 21 15 3

44 44 22 15 3

46 46 23 18 0

48 48 24 18 0

50 50 25 18 3

52 52 26 18 3

54 54 27 21 0

56 56 28 21 0

58 58 29 21 3

60 60 30 21 3

62 62 31 24 0

16 18 19 22

3 1 0 1

3

1

3

1

3

1

3

1

3

1

3

1

3

1

3

1

3

3

1

1

3

3

1

1

3

1

3

3

1

2 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

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

333282E 71

Parts

Color Change Control Module Kits

IS Color Change Control Modules

72 333282E

304

305

307

308

Ref.

No.

Part No. Description

301

302

— — — PANEL

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

315

316

317

24U567

119162

116343

123691

COVER

CONNECTOR, 6–position

SCREW, ground; M5 x 0.8

HOLDER, fuse

15T636 MANIFOLD

121324 SOLENOID

16M007 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)

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

7

1

1

4

3

2

1

1

1

1

6

2

4

Parts

Ref.

No.

Part No. Description

318 112698 ELBOW; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

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

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

OD

321 — — — STRAP, tie

322 — — — FERRULE

324 109193 ELBOW, connector; 10–32 (m) x 5/32 in. (4 mm) OD tube

331 16U743 SPACER

332 16U744 PLATE, non-conductive

333 16U745 PLATE, ground

334 16U746 SCREW, pan-head; 4–40

335 16W501 LABEL, instructions

336 — — — NUT, jam

339 102794 NUT, hex

Qty

2

1

1

2

1

3

6

1

1

2

7

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

Parts labeled — — — are not available separately.

333282E 73

Parts

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

24T776

24T777

24T778

24T779

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

8

10

12

16

4 color and

4 catalyst

6 color and

4 catalyst

10

12

8 color and

4 catalyst

12 color and

4 catalyst;

13–30 color

14

18

13–18 color 6

Solenoid

(310)

6

Plug (313)

24

20

16

12

4

16

12

8

0

24

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

60 ft (18.3 m) 24

70 ft (21.3 m) 28

90 ft (27.4 m) 36

30 ft. (9.1 m) 12

8

10

12

16

10

12

14

18

6

74 333282E

Parts

Expansion Kits

To add colors/catalysts, order the correct IS Expansion Kit.

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 33

for instructions.

Low Pressure Expansion Kits High Pressure Expansion Kits

Kit No.

Without Manifold

24T449

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.

One log-pressure plug.

24T519

With Manifold

26A058 (sst manifold)

26A059 (sst manifold)

26A054 (sst manifold)

26A055 (sst manifold)

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.

SST Manifold Without Valves

24Y989 Manifold with fittings for non-circulating valves. Includes fittings, connecting rods, and o-rings. Also order two solenoid kits (121324), one for each valve.

24Y990 Manifold with fittings for circulating valves. Includes fittings, connecting rods, and o-rings.

Also order two solenoid kits

(121324), one for each valve.

Kit No.

Without Manifold

24T712

24T713

24T723

With Manifold

24T714

24T715

24T716

24T717

Kit Description

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.

One high-pressure plug.

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

With Manifold

24T719

24T720

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

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.

333282E 75

Parts

Air/Solvent Chop Expansion Kits

To add the capability to purge the spray device with an air/solvent chop, order the correct Air Purge Valve Kit.

Air Purge Valve Kits

The following kits are available to provide an air purge valve, used to perform air/solvent chop to purge a spray device. 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. If you plan on using an existing valve, order just the air supply kit. See

Connect the Air Purge Valve, page 25

for instructions.

Low Pressure Kits High Pressure Kits

Kit No.

Without Manifold

26A309

Kit Description Kit No.

Without Manifold

26A333

Kit Description

One non-circulating valve

(replaces a plug). Includes valve,

IS solenoid, fittings, tubing, air regulator, and air supply valves.

One non-circulating valve

(replaces a plug). Includes valve,

IS solenoid, fittings, tubing, air regulator, and air supply valves.

With Manifold

26A310

(sst manifold)

Manifold with one non-circulating valve. Includes valve, plug,

IS solenoid, fittings, tubing, air regulator, and air supply valves.

With Manifold

26A334

(sst manifold)

Manifold with one non-circulating valve. Includes valve, plug,

IS solenoid, fittings, tubing, air regulator, and air supply valves.

Air Supply Kit

For use with both low pressure and high pressure systems. Order this kit if using an existing valve as an air purge valve.

Kit No.

26A311

Kit Description

Air regulator, air supply valves, and tubing.

76 333282E

Parts

Hose Selection

Hose Selection Tool

Use this chart to determine the proper size hoses for your mix ratio and viscosity., then select hoses for your application.

NOTE: Always use Graco hoses.

NOTE: Shaded areas may use hose sizes from either of the two adjacent areas.

Recommended Hose Sizes (internal diameter) for A and B

20 - 50

Mix

Ratio

(X:1)

18

16

14

12

10

8

6

4

2

3/8ʺ A

1/8ʺ B

3/8ʺ A

1/4ʺ B

0

10:1

Thick Resin (A)

Thin Catalyst (B)

7.5:1 5:1 2.5:1 1:1

Equal Viscosities

1:2.5

Viscosity Ratio (Resin [A] : Catalyst [B]

1:5

1/4ʺ A

1/4ʺ B

1:7.5

1/4ʺ A

3/8ʺ B

1:10

Thin Resin (A)

Thick Catalyst (B)

333282E 77

Parts

1/4 in. (6 mm) ID Hoses

Application Material Pressure

Catalyst

Resin

Solvent

Atomizing

Air

Moisture-

Lok

Nylon

Nylon

Nylon

Nylon

High and

Low

Low

High

Low

High

Low

High

Low

Maximum Fluid Working

Pressure

2000 psi (13.8 MPa, 138 bar)

225 psi (1.6 MPa, 16 bar)

4100 psi (28.3 MPa, 283 bar)

225 psi (1.6 MPa, 16 bar)

4100 psi (28.3 MPa, 283 bar)

225 psi (1.6 MPa, 16 bar)

4100 psi (28.3 MPa, 283 bar)

225 psi (1.6 MPa, 16 bar)

Length

15 ft

(4.6 m)

947078

17C967

238825

17C967

238825

17C967

238825

17C967

25 ft

(7.6 m)

24T134

24T266

239107

24T266

239107

24T266

239107

24T194

50 ft

(15.2 m)

24T135

24T267

239111

24T267

239111

24T267

239111

24T195

78 333282E

Dimensions

Dimensions

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)

T

3.84 in. (98 mm)

U

11.44 in. (291 mm)

V

0.312 in. (8 mm) diameter

333282E 79

Dimensions

Figure 26 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)

80 333282E

Dimensions

Figure 27 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)

333282E 81

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:

Valve manifold

Valve

U.S.

Metric

300 psi

1500 psi

100 psi

2.1 MPa, 21 bar

10.5 MPa, 105 bar

0.7 MPa, 7.0 bar

85–100 psi

5/32 in. OD tube

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

Glass-filled polyphenylene sulfide, 316 SST, PTFE, chemically resistant o-rings, FEP encapsulated fluoroelastomer o-rings

See valve manual 332454.

82 333282E

Notes

Notes

333282E 83

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 E, April 2017

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