Graco 332455G, Color Change Kits Instruction

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Graco 332455G, Color Change Kits Instruction | Manualzz
Instructions-Parts
Color Change Kits
332455G
EN
To add optional color change function to ProMix® PD2K Electronic Proportioners. Kits include low or
Non--IS or IS control module.
high pressure color/catalyst change valves and a Non
For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual and in your PD2K
proportioner manual.
Save these instructions.
See page 4 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Related Manuals ................................................ 3
Models............................................................... 4
Non-Intrinsically Safe Kits ............................. 4
Intrinsically Safe Kits .................................... 6
Warnings ........................................................... 7
Important Isocyanate (ISO) Information ................ 10
Isocyanate Conditions .................................. 10
Material Self-ignition..................................... 10
Keep Components A and B Separate ............ 10
Moisture Sensitivity of Isocyanates................ 10
Changing Materials ...................................... 11
Setup the Modules.............................................. 12
Setup Non-IS Control Modules...................... 12
Setup IS Control Modules ............................. 17
Installation.......................................................... 20
Mounting the Color Change Control
Module........................................... 20
Air Supply.................................................... 20
Grounding ................................................... 20
Non-Hazardous Location .............................. 21
Install the Valve Manifolds ............................ 23
Hazardous Location ..................................... 24
Install the Remote Valve Manifolds................ 25
Install the Back Pressure Regulator (High
Pressure Systems Only).................. 27
2
Connect the Valve Air Lines.......................... 27
Connect the Fluid Lines................................ 30
Install an Expansion Kit ................................ 39
Troubleshooting.................................................. 41
Color Change Solenoid Valves ..................... 41
Color Change Board .................................... 43
Electrical Schematics.......................................... 45
Optional Cables and Modules ....................... 51
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
Non-IS Color Change Kits ............................ 57
IS Color Change Kits.................................... 59
Valve Manifolds ........................................... 61
Color Change Control Module Kits ................ 72
Expansion Kits............................................. 77
Dimensions ........................................................ 79
Weights ............................................................. 82
Technical Data ................................................... 87
Graco Standard Warranty.................................... 88
332455G
Related Manuals
Related Manuals
Manual No.
Description
Manual No.
Description
3A2800
PD2K Proportioner Repair-Parts
Manual, Manual Systems
332709
332457
PD2K Proportioner Installation
Manual, Manual Systems
ProMix PD2K Proportioner for
Automatic Spray Applications
Repair-Parts Manual
332458
ProMix PD2K Proportioner for
Automatic Spray Applications
Installation Manual
332564
ProMix PD2K Proportioner for
Automatic Spray Applications
Operation Manual
333282
Color Change and Remote Mix
Manifold Kits Instructions-Parts
Manual
332562
PD2K Proportioner Operation
Manual, Manual Systems
3A2801
Mix Manifold Instructions-Parts
Manual
332339
Pump Repair-Parts Manual
332454
Color Change Valve Repair-Parts
Manual
332456
3rd and 4th Pump Kits
Instructions-Parts Manual
332455G
3
Models
Models
Non--Intrinsically Safe Kits
Non
See the module identification label for product part number, maximum air working pressure, and approval
information and certification.
Figure 1 Non-Intrinsically Safe Color Change Control
Module Label
Kit No.
SST
Series
Kit Description
LW
Maximum Air Working
Maximum Fluid Working
Pressure (Control Module) Pressure (Valves)
Non--Circulating Color Change Kits
Low Pressure Non
25A239
24X316
A
1 color or
1 catalyst
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24Y954
24R915
A
2 color or
2 catalyst
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24Y955
24R916
A
4 color or
4 catalyst
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24Y956
24R917
A
6 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24Y957
24R918
A
8 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
Low Pressure Circulating Color Change Kits
25A240
24X317
A
1 color or
1 catalyst
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24Y958
24R919
A
2 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24Y959
24R920
A
4 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24Y960
24R921
A
6 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24Y961
24R922
A
8 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
Kit Description
Maximum Air Working
Maximum Fluid Working
Pressure (Control Module) Pressure (Valves)
Kit No.
4
Series
332455G
Models
Kit No.
Series
Kit Description
Maximum Air Working
Maximum Fluid Working
Pressure (Control Module) Pressure (Valves)
Non--Circulating Color Change Kits
High Pressure Non
24X318
A
1 color or
1 catalyst
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24R959
A
2 color or
2 catalyst
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24R960
A
4 color or
4 catalyst
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24R961
A
6 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24R962
A
8 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
Non--Circulating Catalyst Change Kits
High Pressure Acid Compatible Non
24X320
A
1 catalyst
(acid compatible)
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24T579
A
2 catalyst
(acid compatible)
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24T580
A
4 catalyst
(acid compatible)
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
High Pressure Circulating Color Change Kits
24X319
A
1 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24R963
A
2 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24R964
A
4 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24R965
A
6 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24R966
A
8 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
332455G
5
Models
Intrinsically Safe Kits
See the module identification label for product part number, maximum air working pressure, and approval
information and certification.
Figure 2 Intrinsically Safe Color Change Control
Module Label
0359
Kit No.
Series
II 2 G
Kit Description
Maximum Air Working Pressure
(Control Module)
Maximum Fluid Working
Pressure (Valves)
Non--Circulating Color Change Kits
Low Pressure Non
24T343
A
2 color or 2 catalyst
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24T344
A
4 color or 4 catalyst
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24T345
A
6 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24T346
A
8 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
Low Pressure Circulating Color Change Kits
24T347
A
2 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24T348
A
4 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24T349
A
6 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
24T350
A
8 color
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
Non--Circulating Color Change Kits
High Pressure Non
24T351
A
2 color or 2 catalyst
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24T352
A
4 color or 4 catalyst
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24T353
A
6 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24T354
A
8 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
High Pressure Circulating Color Change Kits
24T355
A
2 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24T356
A
4 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24T357
A
6 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
24T358
A
8 color
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
6
332455G
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock, Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
332455G
7
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 gun, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
•
•
•
•
•
•
Do not spray without tip guard and trigger guard installed.
Engage trigger lock when not spraying.
Do not point gun at anyone or at any part of the body.
Do not put your hand over the spray tip.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure when you stop spraying/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.
8
332455G
Warnings
WARNING
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.
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.
332455G
9
Important Isocyanate (ISO) Information
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two
component materials.
Keep Components A and B Separate
Isocyanate Conditions
Spraying or dispensing materials containing
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
Read material manufacturer’s warnings and
material MSDS to know specific hazards and
precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors,
and atomized particulates by providing sufficient
ventilation in the work area. If sufficient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.
To prevent contact with isocyanates, appropriate
personal protective equipment, including
chemically impermeable gloves, boots, aprons,
and goggles, is also required for everyone in the
work area.
Self--ignition
Material Self
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and material MSDS.
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
• Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming small, hard, abrasive
crystals, which become suspended in the fluid.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
10
332455G
Important Isocyanate (ISO) Information
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.
332455G
11
Setup the Modules
Setup the Modules
Non--IS Control Modules
Setup Non
NOTE: The PD2K System can use up to four pumps
and six color change modules in the non-hazardous
area. First, determine the number of pumps (both
color and catalyst) in the system pump configuration.
Second, find the appropriate table below that matches
the system pump configuration to understand how
many color change modules are needed for the
number of pumps in your system, and which module
should be associated to which pump.
All Non-IS modules ship from the factory addressed
and labeled as Module 1 (Colors 1–8). Labels
for Modules 2 through 6 are provided with the
module kit. Affix the labels according to your system
configuration.
Total Pumps = 1 (1 Color
Color))
Pump 1:
Color
Module 1
Color
Valves:
1–8
Module 2
Color
Valves:
9–16
Module 3
Color
Valves:
17–24
Module 4
Color
Valves:
25–30
Pump 2:
N/A
Pump 3:
N/A
Pump 4:
N/A
Color,, 1 Catalyst
Catalyst))
Total Pumps = 2 (1 Color
Pump 1:
Color
Pump 2:
Catalyst
Module 1
Color
Valves:
1–8
Module 5
Catalyst
Valves:
1–4
Pump 4:
N/A
Module 2
Color
Valves:
9–16
Module 3
Color
Valves:
17–24
Module 4
Color
Valves:
25–30
Color))
Total Pumps = 2 (2 Color
Pump 1:
Color
Pump 2:
N/A
Pump 3:
Color
Module 1
Color
Valves:
1–8
Module 3
Color
Valves:
17–24
Module 2
Color
Valves:
9–16
Module 4
Color
Valves:
25–30
Pump 4:
N/A
Color,, 1 Catalyst
Catalyst))
Total Pumps = 3 (2 Color
Pump 1:
Color
Pump 2:
N/A
Pump 3:
Color
Module 1
Color
Valves:
1–8
Module 5
Catalyst
Valves:
1–4
Module 3
Color
Valves:
17–24
Module 2
Color
Valves:
9–16
12
Pump 3:
N/A
Pump 4:
N/A
Module 4
Color
Valves:
25–30
332455G
Setup the Modules
Color))
Total Pumps = 3 (3 Color
Pump 1:
Color
Pump 2:
N/A
Module 1
Color
Valves:
1–8
Color,, 2 Catalyst
Catalyst))
Total Pumps = 4 (2 Color
Pump 3:
Color
Pump 4:
Color
Pump 1:
Color
Pump 2:
Catalyst
Pump 3:
Color
Pump 4:
Catalyst
Module 3
Color
Valves:
17–24
Module 4
Color
Valves:
25–30
Module 1
Color
Valves:
1–8
Module 5
Catalyst
Valves:
1–2*
Module 3
Color
Valves:
17–24
Module 6
Catalyst
Valves:
3–4*
Module 2
Color
Valves:
9–16
Module 2
Color
Valves:
9–16
Color,, 1 Catalyst
Catalyst))
Total Pumps = 4 (3 Color
Pump 1:
Color
Pump 2:
Catalyst
Pump 3:
Color
Pump 4:
Color
Module 1
Color
Valves:
1–8
Module 5
Catalyst
Valves:
1–4
Module 3
Color
Valves:
17–24
Module 4
Color
Valves:
25–30
Module 2
Color
Valves:
9–16
Color))
Total Pumps = 4 (4 Color
Pump 1:
Color
Pump 2:
Color
Pump 3:
Color
Pump 4:
Color
Module 1
Color
Valves:
1–8
Module 2
Color
Valves:
9–16
Module 3
Color
Valves:
17–24
Module 4
Color
Valves:
25–30
332455G
Module 4
Color
Valves:
25–30
* If the alternate catalyst valve mapping is enabled,
see note below.
NOTE: For a system with two catalyst pumps that
requires one pump to change among three catalysts,
an alternate valve map may be enabled that will
instead include Catalyst Valves 1–3 on Pump 2
(Module 5) and only include Catalyst Valve 4 on
Pump 4 (Module 6 if color change is still used for this
pump). See Pump Screen 1 in Operation Manuals
332562 and 332564 for details.
NOTE: For a system that uses a mix-at-wall manifold,
and also has more than one gun, the number of
colors is limited to a total of 26. Colors 15 and 16 (on
Module 2) and colors 29 and 30 (on Module 4) are
not available. See Operation Manuals 332562 and
332564 for details on using multiple guns.
13
Setup the Modules
Configure each module according to its designated
number, as follows:
NOTICE
Non--IS Control Module Switch Settings
Non
Control
Module
To avoid damaging the circuit boards, wear Part
No. 112190 grounding strap on your wrist and
ground appropriately.
Module 1
To avoid electrical component damage, remove all
system power before plugging any connectors.
Module 2
1. Remove electrical power from the system.
2. Open the color change module. Locate switches
S4, S5, and S6 on the control module board. The
switches are shipped in the OFF position.
Module 3
Module 4
Module 5
3. For each module, set the switches to ON or OFF,
as shown in the following table.
Module 6
S6
S5
S4
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
4. Use the following figure and tables to determine
the solenoid valve assigned to each valve in the
valve manifold.
NOTE: There can be only one solvent valve and one
dump valve per pump.
Inlet Manifold
Outlet Manifold
Figure 3 Non-IS Control Module
14
332455G
Setup the Modules
Non--IS Control Module 1
Non
Inlet Manifold
Non--IS Control Module 4
Non
Outlet Manifold
Inlet Manifold
Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
Solvent
1
Dump
1
(Solvent)*
1
(Dump)*
2
Color 1
2
Color 1
2
Color 25
2
Color 25
3
Color 2
3
Color 2
3
Color 26
3
Color 26
4
Color 3
4
Color 3
4
Color 27
4
Color 27
5
Color 4
5
Color 4
5
Color 28Ɨ
5
Color 28Ɨ
6
Color 5
6
Color 5
6
Color 29Ɨ
6
Color 29Ɨ
7
Color 6
7
Color 6
7
Color 30
7
Color 30
8
Color 7
8
Color 7
8
Not Used
8
Not Used
9
Color 8
9
Color 8
9
Not Used
9
Not Used
Non--IS Control Module 5
Non
Non--IS Control Module 2
Non
Inlet Manifold
Inlet Manifold
Outlet Manifold
Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
(Solvent)*
1
(Dump)*
1
(Solvent)*
1
(Dump)*
2
Color 9
2
Color 9
2
Catalyst 1
2
Catalyst 1
3
Color 10
3
Color 10
3
Catalyst 2
3
Catalyst 2
4
Color 11
4
Color 11
4
Catalyst 3
4
Catalyst 3
5
Color 12
5
Color 12
5
Catalyst 4
5
Catalyst 4
6
Color 13
6
Color 13
6
Not Used
6
Not Used
7
Color 14
7
Color 14
7
Not Used
7
Not Used
8
Color 15Ɨ
8
Color 15Ɨ
8
Not Used
8
Not Used
9
Color 16Ɨ
9
Color 16Ɨ
9
Not Used
9
Not Used
Non--IS Control Module 3
Non
Inlet Manifold
Outlet Manifold
Solenoid
Valve
Solenoid
Valve
1
(Solvent)*
1
(Dump)*
2
Color 17
2
Color 17
3
Color 18
3
Color 18
4
Color 19
4
Color 19
5
Color 20
5
Color 20
6
Color 21
6
Color 21
7
Color 22
7
Color 22
8
Color 23
8
Color 23
9
Color 24
9
Color 24
332455G
* There should be only one solvent valve and one
dump valve per pump.
Ɨ These colors are not available for systems using
mix-at-wall and have more than one gun.
15
Setup the Modules
Non--IS Control Module 6 (default mapping)
Non
Inlet Manifold
Non--IS Control Module 6 (alternate mapping)
Non
Outlet Manifold
Inlet Manifold
Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
(Solvent)*
1
(Dump)*
1
(Solvent)*
1
(Dump)*
2
Catalyst 3
2
Catalyst 3
2
Catalyst 4
2
Catalyst 4
3
Catalyst 4
3
Catalyst 4
3
Not Used
3
Not Used
4
Not Used
4
Not Used
4
Not Used
4
Not Used
5
Not Used
5
Not Used
5
Not Used
5
Not Used
6
Not Used
6
Not Used
6
Not Used
6
Not Used
7
Not Used
7
Not Used
7
Not Used
7
Not Used
8
Not Used
8
Not Used
8
Not Used
8
Not Used
9
Not Used
9
Not Used
9
Not Used
9
Not Used
* There should be only one solvent valve and one dump valve per pump.
16
332455G
Setup the Modules
Setup IS Control Modules
NOTE: Two color change control modules may be
installed in the hazardous area. The modules are
labeled 7 or 8. An alternate label is provided with
the module kit for Module 8 (Colors 13–30). Affix the
label according to your system configuration.
Configure each module according to its designated
number, as follows:
3. For each module, set the switches to ON or OFF,
as shown in the following table.
IS Control Module Switch Settings
Control
Module
Module 7
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.
Module 8
S6
S5
S4
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
4. Use the following figure and tables to determine
the solenoid valve assigned to each valve in the
valve manifold.
2. Open the color change module. Locate switches
S4, S5, and S6 on the control module board. The
switches may be shipped in the OFF position.
Figure 4 IS Control Module
332455G
17
Setup the Modules
IS Control Module 7
Inlet Manifold
IS Control Module 8
Outlet Manifold
Inlet Manifold
Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
Color
Solvent
1
Catalyst
Solvent
1
Color 13
1
Color 22
2
Color 14
2
Color 23
2
Color 1
2
Catalyst 1
3
Color 15
3
Color 24
3
Color 2
3
Catalyst 2
4
Color 16
4
Color 25
4
Color 3
4
Catalyst 3
5
Color 17
5
Color 26
5
Color 4
5
Catalyst 4
6
Color 18
6
Color 27
6
Color 5
6
Color 9
7
Color 19
7
Color 28
7
Color 6
7
Color 10
8
Color 20
8
Color 29
8
Color 7
8
Color 11
9
Color 21
9
Color 30
9
Color 8
9
Color 12
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 these colors onto a single IS color change module
(Module 7). See Pump Screen 1 in Operations Manuals 332562 and 332564 for details.
IS Control Module 7 (alt 1)
Inlet Manifold
IS Control Module 8 (alt 1)
Outlet Manifold
Inlet Manifold
Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
Color
Solvent
1
Catalyst
Solvent
1
Color 7
1
Color 16
2
Color 8
2
Color 23
2
Color 1
2
Catalyst 1
3
Color 9
3
Color 24
3
Color 2
3
Catalyst 2
4
Color 10
4
Color 25
4
Color 3
4
Catalyst 3
5
Color 11
5
Color 26
5
Color 4
5
Catalyst 4
6
Color 12
6
Color 27
6
Color 5
6
Color 19
7
Color 13
7
Color 28
7
Color 6
7
Color 20
8
Color 14
8
Color 29
8
Color 17
8
Color 21
9
Color 15
9
Color 30
9
Color 18
9
Color 22
18
332455G
Setup the Modules
IS Control Module 7 (alt 2)
Inlet Manifold
IS Control Module 8 (alt 2)
Outlet Manifold
Inlet Manifold
Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
Color
Solvent
1
Catalyst
Solvent
1
Color 5
1
Color 14
2
Color 6
2
Color 15
2
Color 1
2
Catalyst 1
3
Color 7
3
Color 16
3
Color 2
3
Catalyst 2
4
Color 8
4
Color 21
4
Color 3
4
Catalyst 3
5
Color 9
5
Color 22
5
Color 4
5
Catalyst 4
6
Color 10
6
Color 23
6
Color 17
6
Color 25
7
Color 11
7
Color 24
7
Color 18
7
Color 26
8
Color 12
8
Color 29
8
Color 19
8
Color 27
9
Color 13
9
Color 30
9
Color 20
9
Color 28
NOTE: For a system that uses a mix-at-wall manifold and also has more than one gun, additional remote
solvent valves are required. These valve maps are shown below. See Operations Manuals 332562 and
332564 for details on using multiple guns.
IS Control Module 7 (multiple guns)
Inlet Manifold
IS Control Module 8 (multiple guns)
Outlet Manifold
Inlet Manifold
Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
Color
Solvent
(Gun 1)
1
Catalyst
Solvent
(Gun 1)
1
Color
Solvent
(Gun 2)
1
Catalyst
Solvent
(Gun 2)
2
Color 1
2
Catalyst 1*
2
Color 13
2
Color 22
3
Color 2
3
Catalyst 2*
3
Color 14
3
Color 23
4
Color 3
4
Catalyst 3*
4
Color 17
4
Color 21
5
Color 4
5
Catalyst 4*
5
Color 18
5
Color 22
6
Color 5
6
Color 9
6
Color 19
6
Color 23
7
Color 6
7
Color 10
7
Color 20
7
Color 24
8
Color 7
8
Color 11
8
Color 21
8
Color 29
9
Color 8
9
Color 12
9
Color
Solvent
(Gun 3)
9
Color 30
* The remote catalyst valve assignment requires special attention when common catalyst materials are used.
See Operations Manuals 332562 and 332564 for details.
332455G
19
Installation
Installation
equipment, fluid, hoses, and stress cause during
operation.
• To avoid electric shock, turn off power at
the main circuit breaker before opening the
enclosure.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
• Do not substitute or modify system components
as this may impair intrinsic safety.
• Do not install equipment approved only for
non-hazardous location in a hazardous location.
See the identification label for the intrinsic safety
rating for your model.
3. Using the equipment as a template, mark the
mounting holes on the wall at a convenient height
for the operator and so the equipment is easily
accessible for maintenance.
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 color
change control module air inlet fitting (317); 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 Color Change Control
Module
1. See Dimensions, page 79.
This equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
Connect a ground wire from the color change module
to a true earth ground.
Intrinsically safe color change modules located in the
hazardous area must be connected to a true earth
ground in the hazardous area.
2. Ensure that the wall and mounting hardware
are strong enough to support the weight of the
20
332455G
Installation
Non--Hazardous Location
Non
NOTE: Non-IS color change control modules provide
control for the pump’s inlet and outlet color/catalyst
change valves. Depending on the number of valves
in the system, as many as six control modules may
be installed in the non-hazardous location.
7. To install additional color control modules (six
maximum), mount the module(s) as described
in Mounting the Color Change Control Module,
page 20. Connect a 5–pin CAN cable from J11
of the previous color control module to J7 of the
next control module.
8. Replace the cover of the PD2K electrical control
box before turning on power to the system.
1. Mount the first non-IS color control module as
described in Mounting the Color Change Control
Module, page 20.
2. Connect the 5–pin CAN cable (109) to J7 on the
color control module (108).
Figure 5 Cable Connector J7 at Non-IS Color
Control Module
Figure 6 Cable Connection at PD2K Electrical
Control Box
NOTICE
To avoid damaging the circuit boards, wear
Part No. 112190 grounding strap on your wrist
and ground appropriately.
To avoid electrical component damage,
remove all system power before plugging any
connectors.
3. Remove electrical power from the system.
4. Remove the cover from the PD2K electrical
control box.
5. Replace the one-cable grommet (at the top of the
control box) with the supplied two–cable grommet
(110). Move the ADM cable to the two-cable
grommet, and install the cable (109).
6. Connect the cable (109) to J2 on the non-IS side
of the isolation board inside the electrical control
box. See Electrical Schematics, page 45 for a list
of M12 CAN cables for use in a non-hazardous
area.
332455G
Figure 7 Detail of Isolation Board Cable Connections
21
Installation
Notes
22
332455G
Installation
Install the Valve Manifolds
NOTE: Always label the color connections to prevent
cross-connections. Label the inlet manifold, outlet
manifold, and each color valve with its assigned color.
The solvent and dump valves should be furthest from
the manifold stack primary inlet or outlet.
1. Install a mounting bracket (101) on the PD2K
with four screws (103). High pressure systems:
For stability, be sure to fasten the bottom screws
(103) to the pump bracket.
with 16 valve positions (14 colors). On high
pressure systems, the supplied bracket (101) will
accommodate a manifold with 14 valve positions
(12 colors). A larger valve stack will require a
customer supplied/sourced bracket.
3. Repeat for the opposite side of the PD2K.
4. Connect the air lines from the solenoids to the
valves. See Connect the Valve Air Lines, page 27.
NOTE: On high pressure systems, see
Install the Back Pressure Regulator (High
Pressure Systems Only), page 27.
5. Connect the fluid supply lines to the valves. See
Connect the Fluid Lines, page 30.
2. Install the inlet and outlet valve manifolds (102)
on the mounting bracket (101) with four screws
(104), washers (105), and nuts (106).
Figure 8 Install the Valve Manifolds
NOTE: On low pressure systems, the supplied
bracket (101) will accommodate a manifold
332455G
23
Installation
Hazardous Location
3. Connect the hazardous location cable (C1) to J7
on the color control module (108).
NOTE: IS color change control modules provide
control for color/catalyst change valves located in the
hazardous location. A maximum of two IS control
modules may be installed in the hazardous location.
See IS Color Change Control Modules, page 74 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 51 for a
list of M12 CAN cables for use in a hazardous area.
Figure 10 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 45.
1. Remove electrical power from the system.
2. Mount the first color control module as described
in Mounting the Color Change Control Module,
page 20.
Figure 11 Detail of Isolation Board Cable
Connections
Figure 9 Intrinsically Safe Cable Connections
24
332455G
Installation
5. Mount a second hazardous location color control
module as described in Mounting the Color
Change Control Module, 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
332455G
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 27.
5. Connect the fluid supply lines to the valves. See
Connect the Fluid Lines, page 30.
25
Installation
Notes
26
332455G
Installation
Install the Back Pressure Regulator
(High Pressure Systems Only)
NOTE: The back pressure regulator is required on
high pressure systems to prevent the system’s feed
pumps from overdriving the dosing pumps during
color change pump flush and color fill operations.
Adjust the back pressure during the dump process to
be approximately 75% of the supply pressure from
the feed pumps, but never more than 300 psi (2.1
MPa, 21 bar) less than the supply pressure.
Install the back pressure regulator (120) and
attaching hardware at the dump valve of the outlet
manifold stack.
1. Screw the tee (122) onto the dump valve fitting of
the outlet manifold stack.
2. Assemble the two nipples (121) to the back
pressure regulator (120). Screw the regulator
assembly into the tee (122) as shown.
3. Install the gauge (123) in the open port of the
tee (122).
4. Connect a 1/4 npt(f) dump line to the downward
facing nipple (121).
5. Connect the fluid supply lines to the valves. See
Connect the Fluid Lines, page 30.
332455G
Figure 12 Install Back Pressure Regulator at Dump
Valve of Outlet Stack
Connect the Valve Air Lines
1. Connect 5/32 in. (4 mm) OD air tubes from the
inlet solenoids to the air inlets of each inlet valve,
using the label inside the color control module as
a guide. See Setup the Modules, page 12.
2. Repeat for the outlet valves.
The figures on the following pages are examples of
possible air line configurations.
27
Installation
Example: Air Plumbing for Inlet and Outlet Color Stack
28
332455G
Installation
Example: Air Plumbing for Remote Color Stack
332455G
29
Installation
Connect the Fluid Lines
Non--Circulating Fluid Lines
Connect Non
NOTE: There can be only one solvent valve (S) and
one dump valve (D) per pump.
NOTE: On high pressure systems, see
Install the Back Pressure Regulator (High Pressure
Systems Only), page 27.
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.
INLET COLOR VALVE STACK
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.
OUTLET COLOR VALVE STACK
Valve Manifold Stack Schematic
30
332455G
Installation
6. Connect a dedicated gun 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 this line to the A side of the mix
manifold at the gun.
7. Connect the supply line for each catalyst to the
corresponding catalyst valve fitting on the inlet
catalyst valve stack.
8. Connect a supply line from the bottom fitting of
the inlet catalyst valve stack to the inlet manifold
of the material B dosing pump.
9. Connect a supply line from the outlet manifold of
the material B dosing pump to the bottom fitting
of the outlet catalyst valve stack.
10. Connect a dedicated gun supply line for each
catalyst to the corresponding catalyst valve fitting
on the outlet catalyst valve stack. Connect the
other end of this line to the B side of the mix
manifold at the gun.
NOTE: If your system uses more colors than
catalysts, branch the catalyst line to connect it to
each mix manifold. Install a check valve on each
branch of the catalyst line.
NOTE: For ease of maintenance, install a ball
valve at all fluid line tees.
Figure 13 Color Change Connections
(Non-Circulating System)
KEY
A
Air inlet
W
Seal weep and
lubrication port
S
Solvent fitting
C1
Color 1 fitting
C2
Color 2 fitting
The figures on the following pages are examples of
possible fluid line configurations.
11. The mix manifold is belt-mounted. Connect a
fluid hose between the manifold outlet and the
gun inlet.
332455G
31
Installation
Example: Fluid Connections for Manual Guns without Circulation
32
332455G
Installation
Example: Fluid Connections for Remote Manifold without Circulation
332455G
33
Installation
Example: Fluid Connections for Remote Manifold System with Multiple Guns
34
332455G
Installation
Connect Circulating Fluid Lines
Circulation valves enable constant circulation of a
color when that color is not being sprayed:
return line (H) to the shutoff valve, to circulate
the color back to the color supply (A).
closed, the system bypasses
• When a color valve is closed
the dosing pump by directing that color from the
inlet color valve to the outlet color valve through
a circulation line, then to a Y fitting at the mix
manifold, then back to the color supply.
NOTE: The fluid shutoff valve (E) must be
closed when spraying, to allow proper ratio
mixing and flow from the gun (G).
c.
open, the circulation line is
• When a color valve is open
shut off. The color is directed through the material
A dosing pump and out to the gun to be mixed and
sprayed, as in normal operation.
Connect a dedicated gun supply line for
each color to the corresponding color valve
(C1, C2, etc.) on the outlet color valve stack.
Connect the other end of this line to the open
branch of the Y fitting (D).
NOTE: There can be only one solvent valve (S) and
one dump valve (D) per pump.
NOTE: On high pressure systems, see
Install the Back Pressure Regulator (High Pressure
Systems Only), page 27.
1. Connect all fluid lines as described in
Connect Non-Circulating Fluid Lines, page 30.
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. Install a Y fitting (D) in the A side of the mix
manifold (F). Install a fluid shutoff valve (E)
in one branch of the Y fitting. Connect a fluid
332455G
Figure 14 Valve Manifold Connections (Circulating
System)
KEY
S
Solvent fitting
C1
Color 1 fitting
C2
Color 2 fitting
R1
Color 1 circulation fitting
R2
Color 2 circulation fitting
35
Installation
Fluid Flow Schematic Diagram in Circulating Mode (Pump Not Shown for Clarity)
KEY
KEY
A
Color supply
G
Spray gun
B
Inlet color stack
H
C
Outlet color stack
Return line to fluid
supply
D
Y fitting at mix manifold
A port
E
Fluid shutoff valve
F
Mix manifold
36
The figures on the following pages are examples
of possible fluid line configurations for a circulation
system.
332455G
Installation
Example: Fluid Connections for Manual Guns with Circulation
332455G
37
Installation
Example: Fluid Connections for Remote Manifold with Circulation
38
332455G
Installation
Install an Expansion Kit
6. Install the valves as follows:
Expansion Kits are available to add
valves or manifolds to your system. See
Expansion Kits, page 77 for available kits.
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 12. 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 45.
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.
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).
Connect fluid lines to the fittings.
8. Install the air fitting(s) (14). Connect the tubing
from the solenoid valve(s) (see step 3) to the
fitting(s).
9. Install the control module cover.
10. Return the unit to service.
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).
332455G
39
Installation
Install an Expansion Kit (Low Pressure
Valve Manifold Shown)
Non-Circulating
Circulating
40
332455G
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. See Maintenance Screen 4 in Operations Manuals 332562 and 332564 for details.
NOTE: Refer to Electrical Schematics, page 45. If the color change valves are not turning on or off correctly, it
could be caused by one of the following.
Cause
Solution
1. Air regulator pressure
set too high or too low.
Check that air pressure is at least 85 psi (0.6 MPa, 6.0 bar). Do not go above 100
psi (0.7 MPa, 7.0 bar).
2. Air or electrical lines
damaged or connections
are loose.
Visually inspect air and electrical lines for kinks, damage, or loose connections.
Service or replace as needed.
3. Solenoid failure.
Check the applicable solenoid’s LED; see Color Change Board, page 43. If lit,
proceed with the following checks. If not lit, go to Cause 4.
Remove the connector for the applicable solenoid and measure voltage across
the pins on the board:
• In a non-hazardous location, replace the solenoid if voltage is 24 Vdc.
• In a hazardous location, replace the solenoid if voltage is between 9–15 Vdc.
Test the valves as explained under Maintenance Screen 4 in your PD2K
Operation manual. Valves should open and close quickly. If the valves actuate
slowly, it could be caused by:
• Air pressure to the valve actuators is too low. See Cause 1.
• Solenoid is clogged. Make sure the air supply has a 5 micron filter installed.
• Something is restricting the solenoid or tubing. Check for air output from the
air line for the corresponding solenoid when the valve is actuated. Clear the
restriction.
332455G
41
Troubleshooting
Cause
Solution
4. Control board or cable If there is no voltage across the pins on the board or it is less than 9 Vdc, check
failure.
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.
42
332455G
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 15 Color Change Board
332455G
43
Troubleshooting
Color Change Board Diagnostics
Component or
Indicator
Description
Diagnosis
D8
LED (green)
Blinks (heartbeat) during normal operation.
D9
LED (green)
Turns on when power is supplied to the
board.
D10
LED (yellow)
Turns on when board is communicating with
electronic control.
D27–D39,
LED (green)
D41, D43–D46
Turn on when a signal is sent to actuate the
related solenoid valve.
F1
44
Fuse, 0.125 A, 125 V
332455G
Electrical Schematics
Electrical Schematics
NOTE: The electrical system block diagram and
electrical schematic illustrates all possible wiring
expansions in a ProMix PD2K system. Some
components shown are not included with all systems.
NOTE: See Optional Cables and Modules, page 51,
for a list of cable options.
COMMUNICATION
MODULE
(24R910) 5
2
CABLE
(15V206)
CABLE
(15V206)
2
CATALYST CHANGE
MODULE 6
6
(24N935)
CATALYST CHANGE
MODULE 5
6
(24N935)
COLOR CHANGE
MODULE 4
6
(24N935)
COLOR CHANGE
MODULE 3
6
(24N935)
2
CABLE
(15V206)
FAN
(24P658)
FAN
(24P658)
ENCODERAND MOTOR
(16P036, 16P037)
WIRE HARN
ESS
(24P684, 24P685)
ENCODERAND MOTOR
(16P036, 16P037)
WIRE HARN
ESS
(24P684, 24P685)
3
CABLE
(121003)
4
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
1
ADVANCED
DISPLAY MODULE
(24E451)
CABLE (16V429)
GFB
INTERFACES
LIGHT
TOWER
(15X472)
COLOR CH
ANGE MODUL
E7
(24R219)
7
1
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
SOLVENT METER (258718)
CABLE
(16V426)
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
UP
DOWN
SOLVENT FLOW SWITCH (120278)
FLOW RATE ANALOG IN
UP
DOWN
PUMP V/P FOR
FLUID REG.
SOLENOID (12132
4)
PRESSURE SWITCH
(121323)
BARRIER
BOARD
(248192)
FLOW RATE ANALOG IN
MAC SERIES 46
SOLENOID
(16P812)
PUMP V/P FOR
FLUID REG.
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
SPLITTER
(16P243)
GCA
MODULE
EFCM
(24N913)
FLOW RATE ANALOG IN
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
MAC SERIES 46
SOLENOID
(16P812)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
CABLE
(16T280)
ENCODERAND MOTOR
(16P036, 16P037)
WIRE HARN
ESS
(24P684, 24P685)
BREAKOUT MODULE PUMP 2
(24N527)
ENCODERAND MOTOR
(16P036, 16P037)
WIRE HARN
ESS
(24P684, 24P685)
BREAKOUT MODULE PUMP 1
(24N527)
FAN
(24P658)
119159
119159
119159
119159
16T072
CAN
IS BOARD
(24M485)
FAN
(24P658)
GUNTRIGGER INPUTS
1 CABLE
(16V426)
16W159
16W159
POWERIN
16W159
16W159
TERMINAL BLOCKS WITH FUSES
FLOW RATE ANALOG IN
TERMINAL
BLOCK
(114095)
3 CABLE
(121227)
2
CABLE
16H078
COLOR CHANGE
MODULE 2
6
(24N935)
48V-10APOWER SUPPLY
(16U820)
3 CABLE
(121227)
24V
POWER
SUPPLY
(16T660)
3
CABLE
(121227)
LINEFILTER
(16V446)
COMMUNICATION
MODULE
(24R910) 5
CABLE (15V206)
CABLE
16T658
COLOR CHANGE
MODULE 1
6
(24N935)
POWER MODULE
(24R257)
2 CABLE
(15V206)
2 CABLE
(15V206)
065161, 065159
RELAY
2 POSITION
SWITCH
(16U725)
COLOR CH
ANGE MODUL
E8
(24R219)
7
MAC SERIES 46
SOLENOID
(16P812)
PUMP V/P FOR
FLUID REG.
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP V/P FOR
FLUID REG.
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
BREAKOUT MODULE PUMP 4
(24N527)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
MAC SERIES 46
SOLENOID
(16P812)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 3
(24N527)
BOOTH CONTR
OL (24M731)
HAZARDOUS LOCATION
NON-HAZARDOUS LOCATION
Figure 16 Electrical System Block Diagram
332455G
45
Electrical Schematics
AWI
GATEWAY
(24R910)
1 2 3 4 5
CAN IS BOARD
(NON IS)
(IS)
(121227)
P3
1
2
3
4
5
6
7
8
9
10
11
12
5
GCAMODULE
EFCM
(24N913)
3
1 2 3 4 5
UNUSED
UNUSED
CABLE
(16T280)
+12VDC
COM
UNUSED
UNUSED
+12VDC
COM
+12VDC
COM
GFBINTERFACE
(121324)
123
SOLVENT CUTOFF (121324)
PWR (RED)
SIG (WHITE)
COM (B
LACK)
SHIELD/GRN
SOLVENT
UNUSED
BARRIER
BOARD
(248192)
UNUSED
1
RED WIRE (065161)
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
METER
(258718)
GROUND BAR
4
25 PIN D-SUB CABLE
(16T659)
BLACK WIRE (065159)
24V
POWER
SUPPLY
(16T660)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
6
1 2 3 4
INLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
OUTLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
V/P FOR FLUID REG.
PUMP 1
8
1 2 3 4
1 2
5 6 7 8
5
6
1 2 3 4 5
1 2 3 4
7
1 2 3 4
SEE DETAILAOR B
PUMP 2
UP
PUMP 1
UP
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP2
8
1 2
5 6 7 8
MANI
FOLD
+-+-+-+-
LINE
FILTER
(16V446)
MAC SERIES 46
(16P812 QTY 2)
N
4
1 2 3 4 5
MANI
FOLD
MAC SERIES 46
(16P812 QTY 2)
L
F2
CABLE
(16T658)
F1
F4
+-+-+-+-
POWER MODULE
(24R257)
N04
FAN PUMP 1
(24P658)
SEE DET
AILAOR B
+24VDC
COM
+24VDC
COM
+ -
F3
N04
ENCODER/MO
TOR
AND
WIRE HARNESS
PUMP1
N03
2 POSITION
SWITCH
(16U725)
3
1 2 3 4
PUMP 1
DOWN
N (BLUE)
L (BROWN)
N03
GRND
48V-10A
POWERSUPPLY
(16U820)
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
14
N L
2
1 2 3 4 5
+48V
COM
+48V
COM
RELAY
3 4
G3000
METER
PUMP 1
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWISTEDPAIR CABLE (16W159)
G3000
METER
PUMP 2
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWISTEDPAIR CABLE (16W159)
L GRND N
BREAKOUT
MODULE
(24N527)
2
3
2
3
1 2 3 4 5
1 2 3 4
1 2 3 4 5
1 2 3 4
1 2 3 4 5 6 7 8 9 1011 12
MOTOR
MOUNTING
SCREW
MOTOR
MOUNTING
SCREW
1 2 3 4 5 6 7 8 9 1011 12
UNUSED
UNUSED
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
1 2
1 2 3 4 5 6 7 8 9 10
PUMP ENCODER AND MOTOR
(16P037)
UNUSED
UNUSED
UNUSED
WIRE HARNESS
(24P685)
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
WIRE HARNESS
(24P684)
L N GRND
UNUSED
UNUSED
UNUSED
BREAKOUT
MODULE
(24N527)
TERMINAL
BLOCK
(114095)
UNUSED
L N GRND
POWER IN
DETAILB, HIG
H PRESSURE
PUMPS (24M
707, 24M715)
DETAILA, LOW PRESSURE
PUMPS (24M706, 24M714)
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
CABLE
(16H078)
1 2 3 4 5 6 7 8 9 10
PUMP ENCODER AND MOTOR
(16P036)
Figure 17 Electrical Schematic, Sheet 2, Part 1
CONTINUED ON THE NEXT PAGE
46
3 4
+48V
COM
+48V
COM
5
1 2 3 4 5
V/P FOR FLUID REG.
PUMP 2
4
1 2 3 4 5
13 A1(+) A2(-)
OUTLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
3
1 2 3 4
1
BREAKO
UT MODULE PUMP 2 (24N527)
7
2
1 2 3 4 5
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
INLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
BREAKOUT
MODULE PUMP
1 (24N527)
GRND (GRN/YEL)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
54 3 2 1
UNUSED
UNUSED
8
5
1
2
3
UNUSED
(121001)
1
2
3
4
5
3
(24M485)
1 2 3 4 5
SPLITTER
(16P243)
1
2
3
4
5
INTEGRATION
GATEWAY
3
5
1
P4
10
+24VDC
COM
+24VDC
COM
4
1
2
3
4
5
CABLE
PUMP 2
DOWN
2
1
2
3
4
5
P4
P3
16T072
1 2 3 4 5
1
1
2
3
4
5
CABLE
4 25 PIN
D-SUB CABLE
(16T659)
3
CABLE
(15V206)
CABLE (16V429)
2
UNUSED
CABLE (121227)
5
4
3
2
1
332455G
FAN PUMP 2
(24P658)
UNUSED
UNUSED
Electrical Schematics
GUN TRIGGER INPUTS
SIG
COM
SIG
COM
SIG
COM
SIG
COM
SIG
COM
SIG
COM
7
1
2
3
4
5
6
7
8
9
10
11
12
FLOW RATE ANALOG IN 1
FLOW RATE ANALOG COMMON 1
FLOW RATE ANALOG IN 2
FLOW RATE ANALOG COMMON 2
FLOW RATE ANALOG IN 3
FLOW RATE ANALOG COMMON 3
FLOW RATE ANALOG IN 4
FLOW RATE ANALOG COMMON 4
SIG
SOLVENT FLOW SWITCH 2 (120278)
COM
SIG
SAFETY INTERLOCK SWITCH
COM
9
1
2
3
4
5
6
GCAMODULE
EFCM
(24N913)
3
4
3
1
1 2 3 4
V/P FOR FLUID REG.
PUMP 3
1 2 3 4
1 2
5 6 7 8
3 4
2
1 2 3 4 5
3
1 2 3 4
BREAKOUT MODULE PUMP 4 (24N527)
4
5
6
1 2 3 4 5
1 2 3 4 5
1 2 3 4
7
1 2 3 4
8
1 2
5 6 7 8
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
MANIFOLD
MAC SERIES 46
(16P812 QTY 2)
MANIFOLD
MAC SERIES 46
(16P812 QTY 2)
+24VDC
COM
+24VDC
COM
PUMP 4
UP
SEE DETAILAOR B
PUMP 4
DOWN
FAN PUMP 3
(24P658)
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
+24VDC
COM
+24VDC
COM
PUMP 3
UP
SEE DETAILAOR B
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 4
PUMP 3
DOWN
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 3
3 4
+48V
COM
+48V
COM
1 2 3 4 5
8
FAN PUMP 4
(24P658)
1 2 3 4 5
7
V/P FOR FLUID REG.
PUMP 4
6
OUTLET TRANSDUCER
PUMP 4
(16P289 OR 16P290)
5
+48V
COM
+48V
COM
4
OUTLET TRANSDUCER
PUMP 3
(16P289 OR 16P290)
1 2 3 4
LIGHT
TOWER
(15X472)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
BREAKOUT MODULE PUMP 3 (24N527)
INLET TRANSDUCER
PUMP 3
(16P289 OR 16P290)
1 2 3 4 5
1
2
3
4
5
ADVANCED
DISPLAY MODULE
(24E451)
INLET TRANSDUCER
PUMP 4
(16P289 OR 16P290)
1
3
(121003)
1
2
3
4
5
4
25 PIN D-SUB CABLE
(16T659)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
2
GFB PRESSURE SWITCH (121323)
SOLVENT FLOW SWITCH 1 (120278)
CABLE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
4 25 PIN
D-SUB CABLE
(16T659)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
119159
1
2
3
4
5
6
7
8
9
10
11
12
G3000
METER
PUMP 3
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
G3000
METER
PUMP 4
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWISTED PAIR CABLE (16W159)
TWISTED PAIR CABLE (16W159)
Figure 18 Electrical Schematic, Sheet 2, Part 2
CONTINUED ON THE NEXT PAGE
332455G
47
Electrical Schematics
FROMCAN IS BOARD (24M485) ON PAGE 2
FROMCAN IS BOARD (24M485) ON PAGE 2
2 CABLE(15V206)
12 34 5
COLOR
CHANGE
MODULE 1
(COLORS
1 THRU 8)
MANIFOLD
FLUSH
COLOR1
COLOR2
COLOR3
COLOR4
COLOR5
COLOR6
COLOR7
COLOR8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
MANIFOLD
J9
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J10
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
J15
J14
DUMP
COLOR1
COLOR2
COLOR3
COLOR4
COLOR5
COLOR6
COLOR7
COLOR8
MANIFOLD
*FLUSH
COLOR9
COLOR10
COLOR11
COLOR12
COLOR13
COLOR14
COLOR15
COLOR16
12 34 5
COLOR
CHANGE
MODULE 2
(COLORS
9 THRU 16)
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3 J15
4
5
6
J16
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J10
J9
J8
6
J14
MANIFOLD
MANIFOLD
+12VDC
COM
+12VDC
COM
+12VDC
COM
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
DUMP*
FLUSH
COLOR9
CATALYST 1
COLOR10
CATALYST 2
COLOR11
CATALYST 3
COLOR12
CATALYST 4
COLOR13
COLOR14
COLOR15
COLOR16
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
COLOR17
COLOR18
COLOR19
COLOR20
COLOR21
COLOR22
COLOR23
COLOR24
12 34 5
COLOR
CHANGE
MODULE 3
(COLORS
17 THRU 24)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J9
6
2
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16 43
J10
MANIFOLD
MANIFOLD
6
5
4
3
2
1
2
1
J14
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J9
6
CABLE
(15V206)
2
CABLE
MANIFOLD
MANIFOLD
6
5
4
3
2
1
DUMP
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
12 34 5
12 34 5
*FLUSH
CATALYST
CHANGE
MODULE 5
(CATALYST
1 THRU 4)
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
*FLUSH
DUMP*
COLOR17
COLOR25
COLOR18
COLOR26
COLOR19
COLOR27
COLOR20
COLOR28
COLOR21
COLOR29
COLOR22
COLOR30
COLOR23
COLOR24
54 3 2 1
(15V206)
2
CABLE
(15V206)
12 34 5
12 34 5
COLOR
CHANGE
MODULE 4
(COLORS
25 THRU 32)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J10
6
5
4
3
2
1
COM
+12VDC
UNUSED
UNUSED
UNUSED
UNUSED
J9
6
J14
MANIFOLD
6
5
4
3
2
1
DUMP*
COLOR25
COLOR26
COLOR27
COLOR28
COLOR29
COLOR30
12 34 5
2
CABLE(15V206)
Figure 19 Electrical Schematic, Sheet 3
* May be unused in some configurations.
CONTINUED ON THE NEXT PAGE
48
332455G
Electrical Schematics
CATALYST
CHANG
E
MODULE 6
(CATALYST
3 THRU 4)
MANIFOLD
FLUSH
CATALYST 3
CATALYST 4
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J8
MANIFOLD
J9
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
6
J15
J14
DUMP
CATALYST 3
CATALYST 4
2
CABLE
(15V206)
12 34 5
54 3 2 1
CATALYST
CHANG
E
MODULE 5
(CATALYST
1 THRU 2)
MANIFOLD
FLUSH
CATALYST 1
CATALYST 2
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
MANIFOLD
J9
6
J14
DUMP
CATALYST 1
CATALYST 2
(15V206)
2
CABLE
12 34 5
12 34 5
COLOR
CHANG
E
MODULE 4
(COLORS
25 THRU 32)
Figure 20 Electrical Schematic, Sheet 3, Alternate
Configuration for Catalyst Change Control
CONTINUED ON THE NEXT PAGE
332455G
49
Electrical Schematics
FROM CAN IS
BOARD (24M485)
ON PAGE 2
NON-HAZARDOUS LOCATION
HAZARDOUS LOCATION
MAN
IFOLD
COLOR FLUSH
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
12 34 5
COLOR
CHANGE
MODULE 7
(COLORS
33 THRU 40)
J8
MAN
IFOLD
J9
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
7
J15
J14
J10
CATALYST FLUSH
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
COLOR 9
COLOR 10
COLOR 11
COLOR 12
1
CABLE
(16V426)
12 34 5
MAN
IFOLD
COLOR 13
COLOR 14
COLOR 15
COLOR 16
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
12 34 5
COLOR
CHANGE
MODULE 8
(COLORS
41 THRU 48)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
MAN
IFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J10
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J9
7
J14
COLOR 22
COLOR 23
COLOR 24
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
1
CABLE
(16V426)
54 3 2 1
5 4 3 21
BOOTH CONTROL
(24M731)
Figure 21 Electrical Schematic, Sheet 3, Hazardous
Location
50
332455G
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 45.
M12 CAN Cables, for Hazardous Locations
Non--Hazardous
CAN Cables, for Non
Locations Only
NOTE: The total length of cable used in the
hazardous location must not exceed 120 ft (36 m).
Cable Part No.
Length ft (m)
Cable Part No.
Length ft (m)
125306
1.0 (0.3)
16V423
2.0 (0.6)
123422
1.3 (0.4)
16V424
3.0 (1.0)
121000
1.6 (0.5)
16V425
6.0 (2.0)
121227
2.0 (0.6)
16V426
10.0 (3.0)
121001
3.0 (1.0)
16V427
15.0 (5.0)
121002
5.0 (1.5)
16V428
25.0 (8.0)
121003
10.0 (3.0)
16V429
50.0 (16.0)
120952
13.0 (4.0)
16V430
100.0 (32.0)
121201
20.0 (6.0)
121004
25.0 (8.0)
121228
50.0 (15.0)
Non--Hazardous
M12 CAN Cables, for Non
Locations Only
Cable Part No.
Length ft (m)
15U531
2.0 (0.6)
15U532
3.0 (1.0)
Cable Part No.
Length ft (m)
15V205
6.0 (2.0)
16T659
2.5 (0.8)
15V206
10.0 (3.0)
16V659
6.0 (1.8)
15V207
15.0 (5.0)
15V208
25.0 (8.0)
15U533
50.0 (16.0)
15V213
100.0 (32.0)
Non--Hazardous
25 Pin D-SUB Cables, for Non
Locations Only
Alternates for Communication Module
Non--Hazardous Locations Only
24W462, for Non
Module Part No.
Module Part No.
CGMDN0*, DeviceNet
CGMPB0*, Profibus
CGMEP0*, Ethernet IP
CGMPN0*, Profinet
* You must purchase Map Token Kit 17C087 for
use with these kits.
332455G
51
Electrical Schematics
Alternates for Color Change Modules
by Part Number (Factory Configuration), for
Non--Hazardous Locations Only
Non
Alternates for Color Change Modules
by Part Number (Factory Configuration), for
Hazardous Locations Only
Module Part No.
Description
Module Part No.
Description
24T557
2 color/2 catalyst
24T571
2 color/2 catalyst
24T558
4 color/4 catalyst
24T572
4 color/2 catalyst
24T559
6 color/6 catalyst
24T573
6 color/2 catalyst
24T560
8 color/8 catalyst
24T574
8 color/2 catalyst
24T774
12 color/2 catalyst
24T775
4 color/4 catalyst
24T776
6 color/4 catalyst
24T777
8 color/4 catalyst
24T778
12 color/4 catalyst
24T779
13–18 color
52
332455G
Repair
Repair
• To avoid electric shock, turn off power at the
main circuit breaker before opening the control
module.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
• Do not substitute or modify system components
as this may impair intrinsic safety.
NOTICE
Figure 22 Remove Retainer
3. Using the other end of the tool (114), screw it all
the way onto the valve (3). Pull the valve from
the manifold.
To avoid damaging the circuit boards, wear Part
No. 112190 grounding strap on your wrist and
ground appropriately.
To avoid electrical component damage, remove all
system power before plugging any connectors.
Replace a Color Valve
Figure 23 Remove the Valve
1. Flush and relieve pressure as described in your
PD2K operation manual.
2. Engage the pins of the tool (114) with the notches
in the retainer (5) and unscrew the retainer.
NOTE: See manual 332454 to repair the valve.
4. Install the valve in the reverse order of
disassembly. Be sure all o-rings are in place
and lubricated, and that the valve is seated
completely in the manifold.
5. Return the system to service.
332455G
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 45.
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 45.
8. Reinstall the cover.
54
NOTE: Replacing the fuse with a non-Graco fuse
voids the IS system safety approval.
Fuse
Part
No.
Description
F1
12369
0
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.
332455G
Repair
Replace the Color Change Board
2. Remove the color change module cover (304).
3. Note where each cable is connected, then
disconnect all cables from the color change
board connectors.
NOTICE
To avoid damaging the circuit boards, wear Part
No. 112190 grounding strap on your wrist and
ground appropriately.
To avoid electrical component damage, remove all
system power before plugging any connectors.
1. Remove electrical power from the system.
4. Remove the seven mounting screws (303) and
the board (302).
5. Install the new board. Reinstall the screws.
6. Reconnect the cables to the proper
connectors, as noted in step 3. See
Electrical Schematics, page 45.
7. Reinstall the cover (304). Restore electrical
power to the system.
Figure 24 Control Module Repair (Non-IS Module
Shown)
332455G
55
Parts
Parts
Non-IS System Shown
Detail of Back Pressure Regulator (High Pressure Outlet Stack only)
56
332455G
Parts
Non--IS Color Change Kits
Non
Ref.
No.
Part
No.
Description
Qty
Ref.
No.
Part
No.
Description
Qty
101
24U237
BRACKET, mounting
1
114
◆
1
102
◆
KIT, manifold, valve
2
TOOL, installation, valve (not
shown)
103
100157
SCREW, cap, hex head;
1/4–20 x 0.375 in. (10 mm)
4
115
598095
TUBE; nylon; 5/32 in. (4 mm)
OD
◆
104
103195
SCREW, cap, hex head;
1/4–20 x 4.0 in. (101 mm)
4
120
238926
1
105
100016
WASHER, lock; 1/4
4
REGULATOR, back pressure;
used on high pressure kits
only (see detail drawing); see
manual 307892
106
100015
NUT, hex; 1/4–20
4
121
166421
2
107
24N346
HOSE, fluid; 1/4 npsm (fbe);
2.5 ft (0.76 m); ptfe
2
NIPPLE; 1/4 npt; sst; used on
high pressure kits only (see
detail drawing)
108
◆
KIT, module, control
1
122
110290
1
109
15V206
CABLE, CAN; 5–pin female;
10 ft (3.05 m)
1
TEE; 1/4 npt(f); sst; used on
high pressure kits only (see
detail drawing)
123
112564
16V819
GROMMET, cable
1
111
24U236
TOOL, repair, valve (not
shown)
1
GAUGE, pressure, fluid; used
on high pressure kits only (see
detail drawing)
1
110
◆ See the following tables for the part number used
in your color change kit.
Non--IS Kits
Low Pressure Non
Kit No.
Kit Description
Standard Valve
Manifold Kits (102)
[see Low Pressure
Valve Manifold
Kits,, page 61 for
Kits
all available kits]
Control Module Tool
(114)
Kit (108) [see
Non--IS Color
Non
Change Control
Modules,, page
Modules
72 for parts]
Tube Length
(115)
Non--Circulating Color Change Kits
Low Pressure Non
25A239◆
24X316
1 color or 1 catalyst
24Y936◆, 24T457
24T557
24U239
30 ft (9.1 m)
24Y954◆
24R915
2 color or 2 catalyst
24Y938◆, 24T458
24T557
24U239
30 ft (9.1 m)
24Y955◆
24R916
4 color or 4 catalyst
24Y942◆, 24T460
24T558
24U239
50 ft (15.2 m)
24Y956◆
24R917
6 color
24Y946◆, 24T462
24T559
24U239
70 ft (21.3 m)
24Y957◆
24R918
8 color
24Y950◆, 24T464
24T560
24U239
90 ft (28.0 m)
Low Pressure Circulating Color Change Kits
25A240◆
24X317
1 color
24Y937◆, 24T395
24T557
24U239
30 ft (9.1 m)
24Y958◆
24R919
2 color
24Y939◆, 24T488
24T557
24U239
30 ft (9.1 m)
24Y959◆
24R920
4 color
24Y943◆, 24T490
24T558
24U239
50 ft (15.2 m)
24Y960◆
24R921
6 color
24Y947◆, 24T492
24T559
24U239
70 ft (21.3 m)
24Y961◆
24R922
8 color
24Y951◆, 24T494
24T560
24U239
90 ft (28.0 m)
◆ Stainless steel kit.
332455G
57
Parts
Non--IS Kits
High Pressure Non
Kit No.
Kit Description
Standard Valve
Manifold Kits
(102) [see
High Pressure
Valve Manifold
Kits,, page 67 for
Kits
all available
kits]
Control Module
Kit (108) [see
Non--IS Color
Non
Change Control
Modules,, page
Modules
72 for parts]
Tool (114)
Tube Length
(115)
Non--Circulating Color Change Kits
High Pressure Non
24X318
1 color or
1 catalyst
24T647
24T557
24U240
30 ft (9.1 m)
24R959
2 color or
2 catalyst
24T648
24T557
24U240
30 ft (9.1 m)
24R960
4 color or
4 catalyst
24T650
24T558
24U240
50 ft (15.2 m)
24R961
6 color
24T652
24T559
24U240
70 ft (21.3 m)
24R962
8 color
24T654
24T560
24U240
90 ft (28.0 m
Non--Circulating Catalyst Change Kits
High Pressure Acid Compatible Non
24X320
1 catalyst
24X360
24T557
24U240
30 ft (9.1 m)
24T579
2 catalyst
24U182
24T557
24U240
30 ft (9.1 m)
24T580
4 catalyst
24U183
24T558
24U240
50 ft (15.2 m)
High Pressure Circulating Color Change Kits
24X319
1 color
24T677
24T557
24U240
30 ft (9.1 m)
24R963
2 color
24T678
24T557
24U240
30 ft (9.1 m)
24R964
4 color
24T680
24T558
24U240
50 ft (15.2 m)
24R965
6 color
24T682
24T559
24U240
70 ft (21.3 m)
24R966
8 color
24T684
24T560
24U240
90 ft (28.0 m
58
332455G
Parts
IS Color Change Kits
Ref.
No.
Part
No.
Description
Qty
Ref.
No.
Part
No.
Description
Qty
101
24U237
BRACKET, mounting
1
108
◆
KIT, module, control
1
102
◆
KIT, manifold, valve; must
be ordered separately. See
Valve Manifolds, page 61 for
available kits.
2
109
16V426
CABLE, CAN, intrinsically
safe; 5–pin female; 10 ft (3.05
m)
1
110
16V819
GROMMET, cable
1
103
100157
SCREW, cap, hex head;
1/4–20 x 0.375 in. (10 mm)
4
111
24U236
TOOL, repair, valve
1
104
103195
SCREW, cap, hex head;
1/4–20 x 4.0 in. (101 mm)
4
114
◆
TOOL, installation, valve
1
115
598095
TUBE; nylon; 5/32 in. (4 mm)
OD
◆
105
100016
WASHER, lock; 1/4
4
106
100015
NUT, hex; 1/4–20
4
107
24N346
HOSE, fluid; 1/4 npsm (fbe);
2.5 ft (0.76 m); ptfe
2
◆ See the following tables for the part number used
in your color change kit.
Low Pressure IS Kits
Kit No.
Kit Description
Standard Valve
Manifold Kits
(102) [see
Low Pressure
Valve Manifold
Kits,, page 61 for
Kits
all available kits]
Control Module Kit (108)
[see IS Color
Change Control
Modules,, page
Modules
74 for parts]
Tool (114)
Tube Length
(115)
Non--Circulating Color Change Kits
Low Pressure Non
24T343
2 color or
2 catalyst
24T458 (2)
24T571
24U239
60 ft (18.3 m)
24T344
4 color or
4 catalyst
24T458,
24T460
24T572
24U239
120 ft (36.6 m)
24T345
6 color
24T458,
24T462
24T573
24U239
210 ft (64.05 m)
24T346
8 color
24T458,
24T464
24T574
24U239
360 ft (109.8 m)
Low Pressure Circulating Color Change Kits
24T347
2 color
24T458,
24T488
24T571
24U239
60 ft (18.3 m)
24T348
4 color
24T458,
24T490
24T572
24U239
120 ft (36.6 m)
24T349
6 color
24T458,
24T492
24T573
24U239
210 ft (64.05 m)
24T350
8 color
24T458,
24T494
24T574
24U239
360 ft (109.8 m)
332455G
59
Parts
High Pressure IS Kits
Kit No.
Kit Description
Standard Valve
Manifold Kits
(102) [see
High Pressure
Valve Manifold
Kits,, page 67 for
Kits
all available
kits]
Control Module Kit (108)
[see IS Color
Change Control
Modules,, page
Modules
74 for parts]
Tool (114)
Tube Length
(115)
Non--Circulating Color Change Kits
High Pressure Non
24T351
2 color or
2 catalyst
24T648 (2)
24T571
24U240
60 ft (18.3 m)
24T353
4 color or
4 catalyst
24T648,
24T650
24T572
24U240
120 ft (36.6 m)
24T353
6 color
24T648,
24T652
24T573
24U240
210 ft (64.05 m)
24T354
8 color
24T648,
24T654
24T574
24U240
360 ft (109.8 m)
High Pressure Circulating Color Change Kits
24T355
2 color
24T648,
24T678
24T571
24U240
60 ft (18.3 m)
24T356
4 color
24T648,
24T680
24T572
24U240
120 ft (36.6 m)
24T357
6 color
24T648,
24T682
24T573
24U240
210 ft (64.05 m)
24T358
8 color
24T648,
24T684
24T574
24U240
360 ft (109.8 m)
60
332455G
Parts
Valve Manifolds
Low Pressure Valve Manifold Kits
Non-Circulating Valve Manifold Kits
Kit No.
Series
SST
LW
24Y936
24T457
A
24Y938
24T458
24Y940
Circulating Valve Manifold Kits
Kit Description
Kit No.
Series
Kit Description
SST
LW
2 valves
24Y937
24T487
A
2 valves
A
3 valves
24Y939
24T488
A
3 valves
24T459
A
4 valves
24Y941
24T489
A
4 valves
24Y942
24T460
A
5 valves
24Y943
24T490
A
5 valves
24Y944
24T461
A
6 valves
24Y945
24T491
A
6 valves
24Y946
24T462
A
7 valves
24Y947
24T492
A
7 valves
24Y948
24T463
A
8 valves
24Y949
24T493
A
8 valves
24Y950
24T464
A
9 valves
24Y951
24T494
A
9 valves
24Y952
24T465
A
10 valves
24Y953
24T495
A
10 valves
24T466
A
11 valves
24T496
A
11 valves
24T467
A
12 valves
24T497
A
12 valves
24T468
A
13 valves
24T498
A
13 valves
24T469
A
14 valves
24T499
A
14 valves
24T470
A
15 valves
24T500
A
15 valves
24T471
A
16 valves
24T501
A
16 valves
24T472
A
17 valves
24T502
A
17 valves
24T473
A
18 valves
24T503
A
18 valves
24T474
A
19 valves
24T504
A
19 valves
24T475
A
20 valves
24T505
A
20 valves
24T476
A
21 valves
24T506
A
21 valves
24T477
A
22 valves
24T507
A
22 valves
24T478
A
23 valves
24T508
A
23 valves
24T479
A
24 valves
24T509
A
24 valves
24T480
A
25 valves
24T510
A
25 valves
24T481
A
26 valves
24T511
A
26 valves
24T482
A
27 valves
24T512
A
27 valves
24T483
A
28 valves
24T513
A
28 valves
24T484
A
29 valves
24T514
A
29 valves
24T485
A
30 valves
24T515
A
30 valves
24T486
A
31 valves
24T516
A
31 valves
332455G
25A605
61
Parts
Valve Manifold Kit Parts
Non-Circulating
Kits
Circulating Kits
62
332455G
Parts
Ref.
No.
Part
No.
Description
Ref.
No.
Part
No.
Description
1
16P259
MANIFOLD, LW
12
104893
O-RING; ptfe
17J100
MANIFOLD, SST
13
24T523
2
111450
O-RING; chemically resistant
FITTING, fluid; 7/16–20 x 1/4
npt(m)
3
24T441
VALVE, for non-circulating
kits; includes item 2
14
111328
CONNECTOR, tube;
10–32(m) x 5/32 in. (4
mm) OD tube
24T442
VALVE, for circulating kits;
includes item 2
15
24T525
ROD, connecting; 3 in. (76
mm)
24R051
PLUG, cc valve
16
24T524
ROD, connecting; 1.5 in. (38
mm)
4
Qty
★
Qty
5
16N256
RETAINER, nut
6
111457
O-RING; ptfe
17
111504
O-RING; chemically resistant
7
24T521
PLATE, outlet, manifold
18
557716
PLUG; 7/16–20
8
24T522
PLATE, end, manifold
19
104644
9
157974
WASHER, plain
PLUG, screw; 10–32 x 0.156
in. (4 mm)
10
104092
SCREW, cap, socket head;
10–24 x 0.625 in. (16 mm)
22
24T441
VALVE, for circulating kits;
includes item 2
11
100179
NUT, hex; 10–24
★
★ See the following tables to determine the quantity
of each part in your valve manifold kit.
Low Pressure Non-Circulating Valve Manifold Kit Part Quantities
Kit No.
Reference Numbers
SST
LW
1
2
3
4
5
6
7
8
10
12
13
14
15
16
17
18
19
24Y936
24T457
1
2
2
0
2
2
1
1
3
3
3
2
0
3
1
2
0
24Y938
24T458
2
4
3
1
4
3
1
1
3
4
4
3
3
0
1
5
2
24Y940
24T459
2
4
4
0
4
3
1
1
3
5
5
4
3
0
1
4
0
24Y942
24T460
3
6
5
1
6
4
1
1
3
6
6
5
3
3
1
7
2
24Y944
24T461
3
6
6
0
6
4
1
1
3
7
7
6
3
3
1
6
0
24Y946
24T462
4
8
7
1
8
5
1
1
3
8
8
7
6
0
1
9
2
24Y948
24T463
4
8
8
0
8
5
1
1
3
9
9
8
6
0
1
8
0
24Y950
24T464
5
10
9
1
10
6
1
1
3
10
10
9
6
3
1
11
2
24Y952
24T465
5
10
10
0
10
6
1
1
3
11
11
10
6
3
1
10
0
24T466
6
12
11
1
12
7
1
1
3
12
12
11
9
0
1
13
2
24T467
6
12
12
0
12
7
1
1
3
13
13
12
9
0
1
12
0
24T468
7
14
13
1
14
8
1
1
3
14
14
13
9
3
1
15
2
24T469
7
14
14
0
14
8
1
1
3
15
15
14
9
3
1
14
0
24T470
8
16
15
1
16
9
1
1
3
16
16
15
12
0
1
17
2
24T471
8
16
16
0
16
9
1
1
3
17
17
16
12
0
1
16
0
24T472
9
18
17
1
18
10
1
1
3
18
18
17
12
3
1
19
2
24T473
9
18
18
0
18
10
1
1
3
19
19
18
12
3
1
18
0
24T474
10
20
19
1
20
11
1
1
3
20
20
19
15
0
1
21
2
332455G
63
Parts
Kit No.
SST
64
Reference Numbers
LW
1
2
3
4
5
6
7
8
10
12
13
14
15
16
17
18
19
24T475
10
20
20
0
20
11
1
1
3
21
21
20
15
0
1
20
0
24T476
11
22
21
1
22
12
1
1
3
22
22
21
15
3
1
23
2
24T477
11
22
22
0
22
12
1
1
3
23
23
22
15
3
1
22
0
24T478
12
24
23
1
24
13
1
1
3
24
24
23
18
0
1
25
2
24T479
12
24
24
0
24
13
1
1
3
25
25
24
18
0
1
24
0
24T480
13
26
25
1
26
14
1
1
3
26
26
25
18
3
1
27
2
24T481
13
26
26
0
26
14
1
1
3
27
27
26
18
3
1
26
0
24T482
14
28
27
1
28
15
1
1
3
28
28
27
21
0
1
29
2
24T483
14
28
28
0
28
15
1
1
3
29
29
28
21
0
1
28
0
24T484
15
30
29
1
30
16
1
1
3
30
30
29
21
3
1
31
2
24T485
15
30
30
0
30
16
1
1
3
31
31
30
21
3
1
30
0
24T486
16
32
31
1
32
17
1
1
3
32
32
31
24
0
1
33
2
332455G
Parts
Low Pressure Circulating Valve Manifold Kit Part Quantities
Kit No.
Reference Numbers
SST
LW
1
2
3
4
5
6
7
8
10
12
13
14
15
16
17
18
19
22
24Y937
24T487
1
2
1
0
2
2
1
1
3
4
4
2
0
3
1
1
0
1
24Y939
24T488
2
4
2
1
4
3
1
1
3
6
6
3
3
0
1
3
2
1
24Y941
24T489
2
4
3
0
4
3
1
1
3
8
8
4
3
0
1
1
0
1
24Y943
24T490
3
6
4
1
6
4
1
1
3
10
10
5
3
3
1
3
2
1
24Y945
24T491
3
6
5
0
6
4
1
1
3
12
12
6
3
3
1
1
0
1
24Y947
24T492
4
8
6
1
8
5
1
1
3
14
14
7
6
0
1
3
2
1
24Y949
24T493
4
8
7
0
8
5
1
1
3
16
16
8
6
0
1
1
0
1
24Y951
24T494
5
10
8
1
10
6
1
1
3
18
18
9
6
3
1
3
2
1
24Y953
24T495
5
10
9
0
10
6
1
1
3
20
20
10
6
3
1
1
0
1
24T496
6
12
10
1
12
7
1
1
3
22
22
11
9
0
1
3
2
1
24T497
6
12
11
0
12
7
1
1
3
24
24
12
9
0
1
1
0
1
24T498
7
14
12
1
14
8
1
1
3
26
26
13
9
3
1
3
2
1
24T499
7
14
13
0
14
8
1
1
3
28
28
14
9
3
1
1
0
1
24T500
8
16
14
1
16
9
1
1
3
30
30
15
12
0
1
3
2
1
24T501
8
16
15
0
16
9
1
1
3
32
32
16
12
0
1
1
0
1
24T502
9
18
16
1
18
10
1
1
3
34
34
17
12
3
1
3
2
1
24T503
9
18
17
0
18
10
1
1
3
36
36
18
12
3
1
1
0
1
24T504
10
20
18
1
20
11
1
1
3
38
38
19
15
0
1
3
2
1
24T505
10
20
19
0
20
11
1
1
3
40
40
20
15
0
1
1
0
1
24T506
11
22
20
1
22
12
1
1
3
42
42
21
15
3
1
3
2
1
24T507
11
22
21
0
22
12
1
1
3
44
44
22
15
3
1
1
0
1
24T508
12
24
22
1
24
13
1
1
3
46
46
23
18
0
1
3
2
1
24T509
12
24
23
0
24
13
1
1
3
48
48
24
18
0
1
1
0
1
24T510
13
26
24
1
26
14
1
1
3
50
50
25
18
3
1
3
2
1
24T511
13
26
25
0
26
14
1
1
3
52
52
26
18
3
1
1
0
1
24T512
14
28
26
1
28
15
1
1
3
54
54
27
21
0
1
3
2
1
24T513
14
28
27
0
28
15
1
1
3
56
56
28
21
0
1
1
0
1
24T514
15
30
28
1
30
16
1
1
3
58
58
29
21
3
1
3
2
1
24T515
15
30
29
0
30
16
1
1
3
60
60
30
21
3
1
1
0
1
24T516
16
32
30
1
32
17
1
1
3
62
62
31
24
0
1
3
2
1
25A605
332455G
65
Parts
Notes
66
332455G
Parts
High Pressure Valve Manifold Kits
Non-Circulating Valve Manifold Kits
Circulating Valve Manifold Kits
Kit No.
Series
Kit
Description
Kit No.
Series
Kit
Description
24T647
A
2 valves
24T677
A
2 valves
24T648
A
3 valves
24T678
A
3 valves
24T649
A
4 valves
24T679
A
4 valves
24T650
A
5 valves
24T680
A
5 valves
24T651
A
6 valves
24T681
A
6 valves
24T652
A
7 valves
24T682
A
7 valves
24T653
A
8 valves
24T683
A
8 valves
24T654
A
9 valves
24T684
A
9 valves
24T655
A
10 valves
24T685
A
10 valves
24T656
A
11 valves
24T686
A
11 valves
24T657
A
12 valves
24T687
A
12 valves
24T658
A
13 valves
24T688
A
13 valves
24T659
A
14 valves
24T689
A
14 valves
24T660
A
15 valves
24T690
A
15 valves
24T661
A
16 valves
24T691
A
16 valves
24T662
A
17 valves
24T692
A
17 valves
24T663
A
18 valves
24T693
A
18 valves
24T664
A
19 valves
24T694
A
19 valves
24T665
A
20 valves
24T695
A
20 valves
24T666
A
21 valves
24T696
A
21 valves
24T667
A
22 valves
24T697
A
22 valves
24T668
A
23 valves
24T698
A
23 valves
24T669
A
24 valves
24T699
A
24 valves
24T670
A
25 valves
24T700
A
25 valves
24T671
A
26 valves
24T701
A
26 valves
24T672
A
27 valves
24T702
A
27 valves
24T673
A
28 valves
24T703
A
28 valves
24T674
A
29 valves
24T704
A
29 valves
24T675
A
30 valves
24T705
A
30 valves
24T676
A
31 valves
24T706
A
31 valves
24X360 (acid-catalyzed)
A
2 valves
24U182 (acid-catalyzed)
A
3 valves
24U183 (acid-catalyzed)
A
5 valves
332455G
67
Parts
Valve Manifold Kit Parts
Non-Circulating
Kits
Circulating Kits
68
332455G
Parts
Ref.
No.
Part No.
Description
Ref.
No.
Part No.
Description
1
16N271
MANIFOLD, for circulating kits
12
104893
O-RING; ptfe
2
111450
O-RING; chemically resistant
13
24T523
24T581
VALVE, for non-circulating
kits; includes item 2
FITTING, fluid; 7/16–20 x 1/4
npt(m)
3
14
111328
CONNECTOR, tube;
10–32(m) x 5/32 in. (4
mm) OD tube
15
24T729
ROD, connecting; 3.290 in.
(84 mm)
Qty
24T582
VALVE, for circulating kits;
includes item 2
24T583
VALVE, for non-circulating,
acid compatible kits; includes
item 2
4
24R052
PLUG, cc valve
5
16N269
RETAINER, nut
6
111457
O-RING; ptfe
7
24T725
PLATE, outlet, manifold
8
24T726
PLATE, end, manifold
10
111820
SCREW, cap, socket head;
10–24 x 0.75 in. (19 mm)
★
Qty
16
24T728
ROD, connecting; 1.645 in.
(42 mm)
18
557716
PLUG; 7/16–20
19
104644
PLUG, screw; 10–32 x 0.156
in. (4 mm)
22
24T581
VALVE, for circulating kits;
includes item 2
★
★ See the following tables to determine the quantity
of each part in your valve manifold kit.
High Pressure Non-Circulating Valve Manifold Kit Part Quantities
Kit No.
Reference Numbers
1
2
3
4
5
6
7
8
10
12
13
14
15
16
18
19
24T647
1
2
2
0
2
2
1
1
3
3
3
2
0
3
2
0
24T648
2
4
3
1
4
3
1
1
3
4
4
3
3
0
5
2
24T649
2
4
4
0
4
3
1
1
3
5
5
4
3
0
4
0
24T650
3
6
5
1
6
4
1
1
3
6
6
5
3
3
7
2
24T651
3
6
6
0
6
4
1
1
3
7
7
6
3
3
6
0
24T652
4
8
7
1
8
5
1
1
3
8
8
7
6
0
9
2
24T653
4
8
8
0
8
5
1
1
3
9
9
8
6
0
8
0
24T654
5
10
9
1
10
6
1
1
3
10
10
9
6
3
11
2
24T655
5
10
10
0
10
6
1
1
3
11
11
10
6
3
10
0
24T656
6
12
11
1
12
7
1
1
3
12
12
11
9
0
13
2
24T657
6
12
12
0
12
7
1
1
3
13
13
12
9
0
12
0
24T658
7
14
13
1
14
8
1
1
3
14
14
13
9
3
15
2
24T659
7
14
14
0
14
8
1
1
3
15
15
14
9
3
14
0
24T660
8
16
15
1
16
9
1
1
3
16
16
15
12
0
17
2
24T661
8
16
16
0
16
9
1
1
3
17
17
16
12
0
16
0
24T662
9
18
17
1
18
10
1
1
3
18
18
17
12
3
19
2
24T663
9
18
18
0
18
10
1
1
3
19
19
18
12
3
18
0
24T664
10
20
19
1
20
11
1
1
3
20
20
19
15
0
21
2
24T665
10
20
20
0
20
11
1
1
3
21
21
20
15
0
20
0
332455G
69
Parts
Kit No.
Reference Numbers
1
2
3
4
5
6
7
8
10
12
13
14
15
16
18
19
24T666
11
22
21
1
22
12
1
1
3
22
22
21
15
3
23
2
24T667
11
22
22
0
22
12
1
1
3
23
23
22
15
3
22
0
24T668
12
24
23
1
24
13
1
1
3
24
24
23
18
0
25
2
24T669
12
24
24
0
24
13
1
1
3
25
25
24
18
0
24
0
24T670
13
26
25
1
26
14
1
1
3
26
26
25
18
3
27
2
24T671
13
26
26
0
26
14
1
1
3
27
27
26
18
3
26
0
24T672
14
28
27
1
28
15
1
1
3
28
28
27
21
0
29
2
24T673
14
28
28
0
28
15
1
1
3
29
29
28
21
0
28
0
24T674
15
30
29
1
30
16
1
1
3
30
30
29
21
3
31
2
24T675
15
30
30
0
30
16
1
1
3
31
31
30
21
3
30
0
24T676
16
32
31
1
32
17
1
1
3
32
32
31
24
0
33
2
24X360
1
2
2
0
2
2
1
1
3
3
3
2
0
3
2
0
24U182
2
4
3
1
4
3
1
1
3
4
4
3
3
0
5
2
24U183
3
6
5
1
6
4
1
1
3
6
6
5
3
3
7
2
70
332455G
Parts
High Pressure Circulating Valve Manifold Kit Part Quantities
Kit No.
Reference Numbers
1
2
3
4
5
6
7
8
10
12
13
14
15
16
18
19
22
24T677
1
2
1
0
2
2
1
1
3
4
4
2
0
3
1
0
1
24T678
2
4
2
1
4
3
1
1
3
6
6
3
3
0
3
2
1
24T679
2
4
3
0
4
3
1
1
3
8
8
4
3
0
1
0
1
24T680
3
6
4
1
6
4
1
1
3
10
10
5
3
3
3
2
1
24T681
3
6
5
0
6
4
1
1
3
12
12
6
3
3
1
0
1
24T682
4
8
6
1
8
5
1
1
3
14
14
7
6
0
3
2
1
24T683
4
8
7
0
8
5
1
1
3
16
16
8
6
0
1
0
1
24T684
5
10
8
1
10
6
1
1
3
18
18
9
6
3
3
2
1
24T685
5
10
9
0
10
6
1
1
3
20
20
10
6
3
1
0
1
24T686
6
12
10
1
12
7
1
1
3
22
22
11
9
0
3
2
1
24T687
6
12
11
0
12
7
1
1
3
24
24
12
9
0
1
0
1
24T688
7
14
12
1
14
8
1
1
3
26
26
13
9
3
3
2
1
24T689
7
14
13
0
14
8
1
1
3
28
28
14
9
3
1
0
1
24T690
8
16
14
1
16
9
1
1
3
30
30
15
12
0
3
2
1
24T691
8
16
15
0
16
9
1
1
3
32
32
16
12
0
1
0
1
24T692
9
18
16
1
18
10
1
1
3
34
34
17
12
3
3
2
1
24T693
9
18
17
0
18
10
1
1
3
36
36
18
12
3
1
0
1
24T694
10
20
18
1
20
11
1
1
3
38
38
19
15
0
3
2
1
24T695
10
20
19
0
20
11
1
1
3
40
40
20
15
0
1
0
1
24T696
11
22
20
1
22
12
1
1
3
42
42
21
15
3
3
2
1
24T697
11
22
21
0
22
12
1
1
3
44
44
22
15
3
1
0
1
24T698
12
24
22
1
24
13
1
1
3
46
46
23
18
0
3
2
1
24T699
12
24
23
0
24
13
1
1
3
48
48
24
18
0
1
0
1
24T700
13
26
24
1
26
14
1
1
3
50
50
25
18
3
3
2
1
24T701
13
26
25
0
26
14
1
1
3
52
52
26
18
3
1
0
1
24T702
14
28
26
1
28
15
1
1
3
54
54
27
21
0
3
2
1
24T703
14
28
27
0
28
15
1
1
3
56
56
28
21
0
1
0
1
24T704
15
30
28
1
30
16
1
1
3
58
58
29
21
3
3
2
1
24T705
15
30
29
0
30
16
1
1
3
60
60
30
21
3
1
0
1
24T706
16
32
30
1
32
17
1
1
3
62
62
31
24
0
3
2
1
332455G
71
Parts
Color Change Control Module Kits
Non--IS Color Change Control Modules
Non
72
332455G
Parts
Ref.
No.
Part
No.
Description
Qty
Ref.
No.
Part
No.
Description
Qty
301
16P855
PANEL
1
316
C06061
MUFFLER
2
302
24T566
BOARD, circuit
1
317
115671
1
302a
123690
FUSE; 125 mA
1
FITTING, connector; 1/8
npt(m) x 1/4 in. (6 mm) OD
tube
303
112324
SCREW, machine, pan head;
4–40 x 0.25 in. (6 mm)
6
318
112698
ELBOW; 1/8 npt(m) x 1/4 in.
(6 mm) OD tube
2
304
24T562
COVER
1
319
590332
119162
CONNECTOR, 6–position
★
TUBE; polyethylene; 1/4 in. (6
mm) OD
1
305
307
116343
SCREW, ground; M5 x 0.8
1
320
598095
1
308
123691
HOLDER, fuse
1
TUBE; nylon; 5/32 in. (4 mm)
OD
309
24T563
MANIFOLD
2
321
———
STRAP, tie
★
310
16P316
SOLENOID
★
322
———
FERRULE
★
311
117831
SCREW, machine, pan head;
6–32 x 0.5 in. (13 mm)
4
324
114263
FITTING, connector; 1/8
npt(m) x 5/32 in. (4 mm) OD
tube
★
312
103833
SCREW, machine, pan head;
10–32 x 0.375 in. (10 mm)
8
332
151395
WASHER
4
313
24T565
PLUG; 5/8–32; includes item
314
★
★ See the following table to determine the quantity of
each part in your control module kit.
314
113418
O-RING; buna-N
14
Parts labeled — — — are not available separately.
315
100139
PLUG, pipe; 1/8 npt
3
Non-IS Control Module Part Quantities
Find your module kit no. in the left column and the desired reference number in the top row to find the part
quantity used in your control module kit.
Kit No.
Kit
Description
6–Position
Connector
(305)
Solenoid
(310)
Plug (313)
Tie Strap
(321)
Ferrule
(322)
Connector
Fitting
(324)
24T557
2 color
6
6
12
4
12
6
24T558
4 color
6
10
8
4
20
10
24T559
6 color
6
14
4
4
28
14
24T560
8 color
6
18
0
4
36
18
332455G
73
Parts
IS Color Change Control Modules
74
332455G
Parts
Ref.
No.
Part No.
Description
Qty
Ref.
No.
Part No.
Description
Qty
301
16U742
PANEL
1
317
115671
1
302
24T566
BOARD, circuit
1
FITTING, connector; 1/8
npt(m) x 1/4 in. (6 mm) OD
tube
302a
123690
FUSE; 125 mA
1
318
112698
112324
SCREW, machine, pan head;
4–40 x 0.25 in. (6 mm)
6
ELBOW; 1/8 npt(m) x 1/4 in.
(6 mm) OD tube
2
303
319
590332
24U567
COVER
1
TUBE; polyethylene; 1/4 in.
(6 mm) OD
1
304
305
119162
CONNECTOR, 6–position
★
320
598095
1
307
116343
SCREW, ground; M5 x 0.8
1
TUBE; nylon; 5/32 in. (4 mm)
OD
308
123691
HOLDER, fuse
1
321
———
STRAP, tie
★
309
15T636
MANIFOLD
2
322
———
FERRULE
★
310
121324
SOLENOID
★
324
109193
ELBOW, connector; 10–32
(m) x 5/32 in. (4 mm) OD tube
★
311
16M007
SCREW, machine, serrated
head; 10–32 x 0.5 in. (13 mm)
4
331
16U743
SPACER
6
312
103833
SCREW, machine, pan head;
10–32 x 0.375 in. (10 mm)
4
332
16U744
PLATE, non-conductive
1
333
16U745
PLATE, ground
1
334
16U746
SCREW, pan-head; 4–40
3
335
C19289
NUT; 4–40
3
313
121628
SCREW, self-sealing; 4–40 x
0.25 in. (6 mm)
★
314
113418
O-RING; buna-N
14
315
100139
PLUG, pipe; 1/8 npt
3
316
C06061
MUFFLER
2
★ See the following table to determine the quantity of
each part in your control module kit.
Parts labeled — — — are not available separately.
IS Control Module Part Quantities
Find your module kit no. in the left column and the desired reference number in the top row to find the part
quantity used in your control module kit.
Kit No.
Kit
Description
6–Position
Connector
(305)
Solenoid
(310)
Plug (313)
Tie Strap
(321)
Ferrule
(322)
Connector
Fitting
(324)
24T571
2 color and
2 catalyst
6
6
24
4
12
6
24T572
4 color and
2 catalyst
6
8
20
4
16
8
24T573
6 color and
2 catalyst
6
10
16
4
20
10
24T574
8 color and
2 catalyst
6
12
12
4
24
12
24T774
12 color and
2 catalyst
6
16
4
4
32
16
24T775
4 color and
4 catalyst
6
10
16
4
20
10
24T776
6 color and
4 catalyst
6
12
12
4
24
12
332455G
75
Parts
Kit No.
Kit
Description
6–Position
Connector
(305)
Solenoid
(310)
Plug (313)
Tie Strap
(321)
Ferrule
(322)
Connector
Fitting
(324)
24T777
8 color and
4 catalyst
6
14
8
4
28
14
24T778
12 color and
4 catalyst
6
18
0
4
36
18
24T779
13–18 color
6
6
24
4
12
6
76
332455G
Parts
Expansion Kits
Non--IS Expansion Kits
Non
The following kits are available to add color valves in a non-IS area. See Install an Expansion Kit, page 39 for
instructions.
Low Pressure Expansion Kits
Kit No.
Kit Description
Without Manifold
High Pressure Expansion Kits
Kit No.
Kit Description
Without Manifold
24T443
One non-circulating valve
(replaces a plug). Includes valve,
solenoid, fittings, and tubing.
24T584
One non-circulating valve
(replaces a plug). Includes valve,
solenoid, fittings, and tubing.
24T444
One circulating valve (replaces a
plug). Includes valve, solenoid,
fittings, and tubing.
24T585
One circulating valve (replaces a
plug). Includes valve, solenoid,
fittings, and tubing.
With Manifold
With Manifold
24T445
Manifold with one non-circulating
valve. Includes valve, plug,
solenoid, fittings, and tubing.
24T586
Manifold with one non-circulating
valve. Includes valve, plug,
solenoid, fittings, and tubing.
24T446
Manifold with one circulating valve.
Includes valve, plug, solenoid,
fittings, and tubing.
24T587
Manifold with one circulating valve.
Includes valve, plug, solenoid,
fittings, and tubing.
24T447
Manifold with two non-circulating
valves. Includes valves, solenoids,
fittings, and tubing.
24T588
Manifold with two non-circulating
valves. Includes valves, solenoids,
fittings, and tubing.
24T448
Manifold with two circulating
valves. Includes valves, solenoids,
fittings, and tubing.
24T589
Manifold with two circulating
valves. Includes valves, solenoids,
fittings, and tubing.
SST Manifold Without Valves
24Y989
24Y990
332455G
Stainless steel manifold with
fittings for non-circulating valves.
Includes fittings, retainers,
connecting rods, and o-rings. Also
order valve kits (24T443) and plug
kits (24T519).
Stainless steel manifold with
fittings for circulating valves.
Includes fittings, retainers,
connecting rods, and o-rings. Also
order valve kits (24T444) and plug
kits (24T519).
High Pressure Acid-Compatible Expansion Kits
Kit No.
Kit Description
Without Manifold
24T590
One non-circulating acidcompatible valve (replaces a
plug). Includes valve, solenoid,
fittings, and tubing.
With Manifold
24T591
Manifold with one non-circulating
acid-compatible valve. Includes
valve, plug, solenoid, fittings, and
tubing.
24T592
Manifold with two non-circulating
acid-compatible valves. Includes
valves, solenoids, fittings, and
tubing.
77
Parts
IS Expansion Kits
The following kits are available to add color valves in an IS area. See Install an Expansion Kit, page 39 for
instructions.
Low Pressure Expansion Kits
Kit No.
Kit Description
Without Manifold
High Pressure Expansion Kits
Kit No.
Kit Description
Without Manifold
24T449
One non-circulating valve
(replaces a plug). Includes valve,
IS solenoid, fittings, and tubing.
24T712
One non-circulating valve
(replaces a plug). Includes valve,
IS solenoid, fittings, and tubing.
24T450
One circulating valve (replaces a
plug). Includes valve, IS solenoid,
fittings, and tubing.
24T713
One circulating valve (replaces a
plug). Includes valve, IS solenoid,
fittings, and tubing.
With Manifold
With Manifold
24T451
Manifold with one non-circulating
valve. Includes valve, plug, IS
solenoid, fittings, and tubing.
24T714
Manifold with one non-circulating
valve. Includes valve, plug, IS
solenoid, fittings, and tubing.
24T452
Manifold with one circulating valve.
Includes valve, plug, IS solenoid,
fittings, and tubing.
24T715
Manifold with one circulating valve.
Includes valve, plug, IS solenoid,
fittings, and tubing.
24T453
Manifold with two non-circulating
valves. Includes valves, IS
solenoids, fittings, and tubing.
24T716
Manifold with two non-circulating
valves. Includes valves, IS
solenoids, fittings, and tubing.
24T454
Manifold with two circulating
valves. Includes valves, IS
solenoids, fittings, and tubing.
24T717
Manifold with two circulating
valves. Includes valves, IS
solenoids, fittings, and tubing.
SST Manifold Without Valves
24Y989
24Y990
78
Stainless steel manifold with
fittings for non-circulating valves.
Includes fittings, retainers,
connecting rods, and o-rings. Also
order valve kits (24T449) and plug
kits (24T519).
Stainless steel manifold with
fittings for circulating valves.
Includes fittings, retainers,
connecting rods, and o-rings. Also
order valve kits (24T450) and plug
kits (24T519).
High Pressure Acid-Compatible Expansion Kits
Kit No.
Kit Description
Without Manifold
24T718
One non-circulating acidcompatible valve (replaces a
plug). Includes valve, IS solenoid,
fittings, and tubing.
With Manifold
24T719
Manifold with one non-circulating
acid-compatible valve. Includes
valve, plug, IS solenoid, fittings,
and tubing.
24T720
Manifold with two non-circulating
acid-compatible valves. Includes
valves, IS solenoids, fittings, and
tubing.
332455G
Dimensions
Dimensions
Figure 25 Non-IS Control Module
A
B
C
D
E
F
11.30 in. (1478
mm)
7.67 in. (195
mm)
9.8 in. (249 mm)
5.70 in. (145
mm)
0.31 in. (8 mm)
5.80 in. (147
mm)
Figure 26 IS Control Module
A
B
C
D
E
F
16.57 in. (421
mm)
8.22 in. (209
mm)
15.07 in. (383
mm)
6.70 in. (170
mm)
0.31 in. (8 mm)
4.52 in. (115
mm)
332455G
79
Dimensions
NOTE: Total height of valve stack = H + K + (J x
number of manifold blocks in your stack).
Figure 27 Manifold
G
H
J
K
L
M
N
P
R
S
0.32 in.
(8 mm)
0.28 in.
(7 mm)
1/4
npt(m)
0.30
in. (7.6
mm)
0.28 in.
(7 mm)
1/4
npt(m)
Low Pressure Valve Manifolds
1.80 in.
(46 mm)
0.48 in.
(12 mm)
1.50 in.
(38 mm)
0.64 in.
(16 mm)
5.03 in.
(128
mm)
3.35 in.
(85 mm)
0.24 in.
(6 mm)
High Pressure Valve Manifolds
2.00 in.
(51 mm)
80
0.61 in.
(15 mm)
1.66 in.
(42 mm)
0.61 in.
(15 mm)
5.4 in.
(137
mm)
3.35 in.
(85 mm)
0.30
in. (7.6
mm)
332455G
Dimensions
T
U
V
3.84 in. (98
mm)
11.44 in. (291
mm)
0.312 in. (8
mm) diameter
Figure 28 Manifold Mounting Bracket
332455G
81
Weights
Weights
Low Pressure Non-Circulating Valve Manifold Kits
(Lightweight)
Kit No.
grams
lb
Low Pressure Circulating Valve Manifold Kits
(Lightweight)
Kit No.
grams
lb
24T457
1.90
863
24T487
2.01
912
24T458
2.82
1277
24T488
2.98
1351
24T459
2.80
1269
24T489
3.01
1366
24T460
3.71
1684
24T490
3.98
1805
24T461
3.69
1675
24T491
4.02
1821
24T462
4.61
2090
24T492
4.98
2260
24T463
4.59
2081
24T493
5.02
2276
24T464
5.50
2496
24T494
5.99
2715
24T465
5.48
2488
24T495
6.02
2731
24T466
6.40
2902
24T496
6.99
3170
24T467
6.38
2894
24T497
7.02
3186
24T468
7.29
3308
24T498
7.99
3625
24T469
7.28
3300
24T499
8.03
3641
24T470
8.19
3715
24T500
8.99
4080
24T471
8.17
3706
24T501
9.03
4096
24T472
9.08
4121
24T502
10.00
4535
24T473
9.07
4112
24T503
10.03
4551
24T474
9.98
4527
24T504
11.00
4989
24T475
9.96
4519
24T505
11.04
5005
24T476
10.88
4933
24T506
12.00
5444
24T477
10.86
4925
24T507
12.04
5460
24T478
11.77
5339
24T508
13.01
5899
24T479
11.75
5331
24T509
13.04
5915
24T480
12.67
5746
24T510
14.01
6354
24T481
12.65
5737
24T511
14.04
6370
24T482
13.56
6152
24T512
15.01
6809
24T483
13.54
6143
24T513
15.05
6825
24T484
14.46
6558
24T514
16.01
7264
24T485
14.44
6550
24T515
16.05
7280
24T486
15.35
6964
24T516
17.02
7719
82
332455G
Weights
Low Pressure Non-Circulating Valve Manifold Kits
(Stainless Steel)
Kit No.
lb
grams
Low Pressure Circulating Valve Manifold Kits
(Stainless Steel)
Kit No.
lb
grams
24Y936
3.90
1769
24Y937
4.01
1819
24Y938
6.82
3093
24Y939
6.98
3166
24Y940
6.80
3084
24Y941
7.01
3180
24Y942
9.71
4404
24Y943
9.98
4527
24Y944
9.69
4395
24Y945
10.02
4545
24Y946
12.61
5720
24Y947
12.98
5888
24Y948
12.59
5711
24Y949
13.02
5906
24Y950
15.50
7031
24Y951
15.99
7253
24Y952
15.48
7022
24Y953
16.02
7267
25A605
21.99
9995
332455G
83
Weights
High Pressure Non-Circulating Valve Manifold Kits
High Pressure Circulating Valve Manifold Kits
Kit No.
lb
grams
Kit No.
lb
grams
24T647
7.7
3503
24T677
7.7
3508
24T648
11.5
5210
24T678
11.5
5216
24T649
11.7
5329
24T679
11.8
5337
24T650
15.5
7036
24T680
15.5
7046
24T651
15.8
7154
24T681
15.8
7167
24T652
19.5
8861
24T682
19.6
8876
24T653
19.8
8980
24T683
19.8
8997
24T654
23.6
10687
24T684
23.6
10706
24T655
23.8
10806
24T685
23.9
10826
24T656
27.6
12512
24T686
27.6
12535
24T657
27.8
12631
24T687
27.9
12656
24T658
31.6
14338
24T688
31.7
14365
24T659
31.9
14457
24T689
31.9
14486
24T660
35.6
16163
24T690
35.7
16195
24T661
35.9
16282
24T691
36.0
16316
24T662
39.7
17989
24T692
39.7
18024
24T663
39.9
18108
24T693
40.0
18145
24T664
43.7
19814
24T694
43.8
19854
24T665
43.9
19933
24T695
44.0
19975
24T666
47.7
21640
24T696
47.8
21684
24T667
48.0
21759
24T697
48.1
21805
24T668
51.7
23465
24T698
51.8
23514
24T669
52.0
23584
24T699
52.1
23634
24T670
55.8
25291
24T700
55.9
25343
24T671
56.0
25410
24T701
56.1
25464
24T672
59.8
27117
24T702
59.9
27173
24T673
60.0
27235
24T703
60.2
27294
24T674
63.8
28942
24T704
63.9
29003
24T675
64.1
29061
24T705
64.2
29124
24T676
67.8
30768
24T706
68.0
30832
24U182 (acidcatalyzed)
11.5
5210
24U183 (acidcatalyzed)
15.5
7036
24X846 (acidcatalyzed)
7.7
3503
84
332455G
Weights
Non-IS Color Change Control Modules
Non-IS Color Change Control Modules
Kit No.
lb
grams
Kit No.
lb
grams
24T557
9.7
4386
24T571
9.1
4122
24T558
10.1
4576
24T572
9.4
4266
24T559
10.5
4766
24T573
9.7
4409
24T560
10.9
4956
24T574
10.0
4553
24T774
10.6
4840
24T775
9.7
4409
24T776
10.0
4553
24T777
10.0
4696
24T778
10.9
4984
24T779
9.1
4122
332455G
85
Notes
Notes
86
332455G
Technical Data
Technical Data
Color Change Kits
Metric
U.S.
Maximum fluid working
pressure:
Low pressure kits
300 psi
2.1 MPa, 21 bar
High pressure kits
1500 psi
10.5 MPa, 105 bar
100 psi
0.7 MPa, 7.0 bar
85–100 psi
0.6–0.7 MPa, 6.0–7.0 bar
Maximum working air
pressure:
Air supply:
20–5000 centipoise
Viscosity range of fluid:
Fluid inlet size:
1/4 npt(f)
Fluid outlet size:
1/4 npt(f)
Air inlet size:
5/32 in. OD tube
Weights:
4 mm OD tube
See Weights, page 82.
Wetted parts:
Light-Weight Valve
manifold
Stainless-Steel Valve
manifold
Valve
332455G
Glass-filled polyphenylene sulfide, 316 SST, PTFE, chemically resistant o-rings
303 SST, 316 SST, PTFE, chemically resistant o-rings
See valve manual 332454.
87
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its
name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.
With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of
twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance
with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be
made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost
profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not
manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of
their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of
these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold
hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices
and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou
en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original Instructions. This manual contains English. MM 332455
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
2013,, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Copyright 2013
www.graco.com
Revision G, September 2015

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