Download Graco 312787G User's Manual

Instructions-Parts
Color Change
Module Kits
312787G
EN
Includes color change valve stack and control module to add or expand color change
function on ProMix® 2KS and ProMix 3KS Electronic Proportioners.
For professional use only.
Approved for use in explosive atmospheres only when used in conjunction with ProMix
2KS or ProMix 3KS Electronic Proportioners.
See page 3 for model information, including maximum working pressure.
Important Safety Instructions
Read all warnings and instructions in this manual. For complete
warnings and instructions see your proportioning system manual.
Hazard symbols refer to specific procedure risks. Save all instructions.
Color Change Kit shown installed in a
ProMix 2KS Proportioning System
TI12828b
Related Manuals
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Low Pressure Kits . . . . . . . . . . . . . . . . . . . . . . . . 3
High Pressure Kits . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install Color Change Control Module . . . . . . . . . 4
Install Color Valve Stacks . . . . . . . . . . . . . . . . . . 7
Connect Valve Air Lines . . . . . . . . . . . . . . . . . . . 7
Connect Valve Fluid Lines . . . . . . . . . . . . . . . . . . 7
Color Change Board Switch Settings . . . . . . . . . 7
Accessory Dump Valve Kit . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Color Change Solenoid Valves . . . . . . . . . . . . . 10
Color Change Board Fuse . . . . . . . . . . . . . . . . 10
Replace a Solenoid . . . . . . . . . . . . . . . . . . . . . . 11
Replace the Color Change Board Fuse . . . . . . 11
Color Change Board Diagnostics . . . . . . . . . . . 12
Replace the Color Change Board . . . . . . . . . . . 13
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 14
System Pneumatic Diagram . . . . . . . . . . . . . . . 14
Color Change Module Electrical Schematic . . . 15
System Electrical Schematic . . . . . . . . . . . . . . . 16
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Low Pressure Color Change Kits . . . . . . . . . . . 18
High Pressure Color Change Kits . . . . . . . . . . . 18
Color Change Control Modules . . . . . . . . . . . . . 20
277752 2-Color Control Module . . . . . . . . . . . . 22
278095 1 Catalyst/1 Flush Control Module
(0 Color) . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 26
2
Related Manuals
See the following manuals for additional information on
the color change module and kits.
Manual
Description
312775
ProMix 2KS Manual System Installation
312776
ProMix 2KS Manual System Operation
312777
ProMix 2KS Manual System
Repair-Parts
312778
ProMix 2KS Automatic System Installation
312779
ProMix 2KS Automatic System Operation
312780
ProMix 2KS Automatic System
Repair-Parts
313881
ProMix 3KS Installation
313882
ProMix 3KS Manual System Operation
313883
ProMix 3KS Repair-Parts
313885
ProMix 3KS Automatic System Operation
312782
Dispense Valve
312783
Color and Catalyst Change Valve Stacks
312786
Dump Valve and Third Purge Valve Kits
312787G
Models
Models
Low Pressure Kits
High Pressure Kits
100 psi (0.7 MPa, 7.0 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7.0 bar) Maximum Air Inlet Pressure
300 psi (2.1 MPa, 21 bar) Maximum Fluid Working
Pressure
3000 psi (21 MPa, 210 bar) Maximum Fluid Working
Pressure
Kit Part No.
Series
Description
Kit Part No.
Series
Description
256581
2 color
256596
2 color
256582
4 color
256597
4 color
256583
7 color
256598
7 color
256584
12 color
256599
12 color
256585
2 color/2 catalyst
256600
2 color/2 catalyst
256586
4 color/2 catalyst
256601
4 color/2 catalyst
256587
4 color/4 catalyst
256602
4 color/4 catalyst
7 color/2 catalyst
256603
256589
7 color/4 catalyst
256604
7 color/4 catalyst
256590
12 color/2 catalyst
256605
12 color/2 catalyst
256591
12 color/4 catalyst
256606
12 color/4 catalyst
256592
13-18 color
256607
13-18 color
256593
13-24 color
256608
13-24 color
256594
13-30 color
256609
13-30 color
256595
1 catalyst/1 flush (0 color)
256610
1 catalyst/1 flush (0 color)
256588
312787G
A
A
7 color/2 catalyst
3
Installation
Installation
Install Color Change Control
Module
• To avoid electric shock, turn off equipment power
and shut off power at main circuit breaker before
installing.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
• Do not substitute system components as this
may impair intrinsic safety.
Location
Install the color change control module (101) near the
fluid station. The module is approved for use in a hazardous location. Also see your system installation manual. See FIG. 1.
Mounting
1. See Dimensions, page 24.
2. Ensure that the wall and mounting hardware are
strong enough to support the weight of the equipment, fluid, hoses, and stress caused during operation.
To reduce the risk of serious injury, including fluid
injection, relieve pressure before installing the kit.
Follow the Pressure Relief Procedure in the
ProMix 2KS Operation or Service manual.
3. Using the equipment as a template, mark the
mounting holes on the wall at a convenient height
for the operator and so equipment is easily accessible for maintenance.
4. Drill mounting holes in the wall. Install anchors as
needed.
5. Bolt equipment securely.
101
FSL
FSL
13
EC
11
SV
11
SV
TI12828b
FIG. 1: Control Module Installation
4
312787G
Installation
Connect Module to Fluid Station Board
NOTICE
To avoid damaging circuit board when servicing, wear
grounding strap on wrist and ground appropriately.
1. Remove the Fluid Station cover.
2. See FIG. 1. Connect a 5-pin electrical cable (EC)
from the labeled connection port
(J11) on the
J11
(Color
Change
Module)
fluid station control board to the color change board.
Also see FIG. 2 and FIG. 5.
NOTE: See Table 1 for a list of available cables to connect the color change control module and fluid station.
Recommended length is 3 ft (1.0 m) or 6 ft (2.0 m).
Table 1: Intrinsically Safe CAN Cables
Part No.
Length in ft (m)
15U531
2 (0.6)
15U532
3 (1.0)
15V205
6 (2.0)
15V206
10 (3.0)
Connect Air Supply to Control Module
15V207
15 (5.0)
15V208
25 (8.0)
15U533
50 (16.0)
Connect a 1/4 in. (6 mm) OD tube (13) between the system’s air manifold (at the bottom rear of the fluid station)
and the module air inlet fitting (29). See FIG. 3.
15V213
100 (32.0)
FIG. 2: Fluid Station Control Board Connection
The air supply must be clean and dry. Use a 5 micron filter. Regulate the air pressure to 75-100 psi (0.52-0.70
MPa, 5.25-7.0 bar).
To Install a Second Control Module
If you are using two color change modules to add colors,
connect a 5-pin electrical cable from the first color
change board to the second color change board. See
FIG. 5.
29
TI12824a
FIG. 3: Solenoid Air Connection
312787G
5
Installation
6
312787G
Installation
Install Color Valve Stacks
Connect Valve Air Lines
1. Install the bracket (17) on the fluid station (FS) with
two screws (20). See FIG. 4.
See FIG. 1. Connect 5/32 in. (4 mm) OD air tubes (11)
from the valve solenoids to the air inlets of each valve.
Refer to the System Pneumatic Diagram, page 14,
and the label inside the color control module.
2. Install the color or catalyst valve stack (VS) to the
bracket (17) with two screws (20).
NOTE: The high pressure color change valves use a
spring-operated exhaust which does not require a second air line.
FS
17
20
Connect Valve Fluid Lines
VS
1. See FIG. 1. Connect fluid supply lines (FSL) to the
1/4 npt(f) inlet of each valve adapter. Supply solvent
to one valve (SV) at the top of the stack,
NOTICE
Verify that all unused fluid ports on the color change
valve stack are plugged before operation. An open
port will leak fluid.
20
2. Connect the hose (19) from the manifold stack fluid
outlet (F) to the flow meter inlet (M). FIG. 4.
TI12829a
M
F
NOTICE
A check valve is recommended on all dead head
valves to prevent color crossover if two valves are
open at the same time.
FIG. 4: Install Valve Stacks
Color Change Board Switch
Settings
Set switches S3-S6 on the color change board(s) as
shown in Table 2 and FIG. 5, depending on the number
of color change boards and color change modules being
used in your system.
Accessory Dump Valve Kit
15V821 Dump Valve Kit, for Wall Panel Systems
15V822 Dump Valve Kit, for RoboMix Systems
Accessory Dump Valve Kits are available. The kits
include one dump valve, one solenoid, all necessary
parts for installation, and instruction manual 312786.
Order one kit for each dump valve desired.
312787G
7
Installation
Table 2: Color Change Board Switch Settings for ProMix 2KS Systems
Two Color Change Boards
Color Change Board 1
Color Change Board 2
S3
S6
S5
S4
S3
S6
S5
S4
Termination
Resistor
Board ID
Catalyst
On/Off
Color
On/Off
Termination
Resistor
Board ID
Catalyst
On/Off
Color
On/Off
OFF
ON
ON
ON
ON
OFF
OFF
ON
OFF
ON
ON
NOT USED
OFF
Effect on System
4 catalyst/30 color valves
0 catalyst/30 color valves
One Color Change Board
ON
ON
ON
ON
ON
ON
ON
OFF
ON
ON
OFF
ON
4 catalyst/12 color valves
NOT PRESENT
4 catalyst/0 color valves
0 catalyst/12 color valves
Table 3: Color Change Board Switch Settings for ProMix 3KS Systems
Two Color Change Boards
Color Change Board 1
Color Change Board 2
S3
S6
S5
S4
S3
S6
S5
S4
Termination
Resistor
Board ID
Catalyst
On/Off
Color
On/Off
Termination
Resistor
Board ID
Component
C On/Off
Color
On/Off
OFF
ON
ON
ON
ON
OFF
OFF
ON
4 catalyst valves, 25
color valves
OFF
ON
OFF
ON
ON
OFF
OFF
ON
0 catalyst valves, 25
color valves
OFF
ON
ON
ON
ON
OFF
ON
ON
4 catalyst valves, 4 component C valves, 25 color
valves
OFF
ON
OFF
ON
ON
OFF
ON
ON
4 component C valves,
25 color valves
Effect on System
One Color Change Board
8
ON
ON
ON
ON
ON
ON
ON
OFF
ON
ON
OFF
ON
4 catalyst valves, 12
color valves
NOT PRESENT
4 catalyst valves, 0 color
valves
0 catalyst valves, 12
color valves
312787G
Installation
Switch S3-S6
Positions
ON
ON
OFF
OFF
TI13661a
S6
S4
S5
J7
S3
FIG. 5. 256172 Color Change Board Switch Settings
312787G
J11
9
Troubleshooting
Troubleshooting
Color Change Solenoid Valves
NOTE: Refer to the Schematic Diagrams, page 14. 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 air pressure. 80-90 psi (550-630 kPa, 5.5-6.3 bar) is commonly used.
Do not go below 75 psi (0.52 MPa, 5.2 bar) or above 100 psi (0.7 MPa, 7 bar).
2. Air or electrical lines damaged or connections 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 FIG. 7 and Table 4). 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. If voltage is between 9-15 Vdc, replace the solenoid.
Manually operate the valves by removing the color change module cover and
pressing and releasing solenoid valve override buttons. FIG. 6.
Valves should snap open and shut 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 air supply has 10 micron filter installed.
• Something is restricting the solenoid or tubing. Check for air output from air
line for corresponding solenoid when valve is actuated. Clear restriction.
4. Fluid station control board or
cable failure.
If there is no voltage across the pins on the board or it is less than 9 Vdc,
check LEDs D9 and D10 (see FIG. 7 and Table 4). If both are lit and functioning properly, or other solenoids in the module are working properly, replace the
color change board.
If D9 and D10 are not lit:
•
•
Check if the cable is disconnected or damaged.
Check the fluid station control board (see the ProMix 2KS Repair-Parts
Manual).
Color Change Board Fuse
Problem
No power to board. Communication
between color change module and
fluid station is interrupted.
10
Cause
Color change board fuse (F1) is
blown.
Solution
Verify condition of fuse. Replace if
necessary. See page 11.
312787G
Troubleshooting
Replace a Solenoid
1. Remove air supply pressure from the system.
Remove the color change module cover (30).
2. Disconnect the 2 solenoid wires from the color
change board (15). See FIG. 7, the Color Change
Module Electrical Schematic on page 15, and the
System Electrical Schematic on page 17.
3. Unscrew 2 screws (P) and remove the solenoid (4).
See FIG. 6.
Replace the Color Change
Board Fuse
NOTE: Replacing the fuse with a non-Graco fuse voids
the IS system safety approval.
Fuse
4. Install the new solenoid (4).
5. Connect the 2 solenoid wires to the color change
board (15). Solenoid wires are polarized (red
+12Vdc, black –). Refer to the Color Change Module Electrical Schematic on page 15 and the System Electrical Schematic on page 17.
Part No.
F1
123690
Description
Fuse; 125 mA, intrinsically safe
1. Remove electrical power from the system. Remove
the color change module cover (30).
2. Locate fuse (F1) on the color change board. See
FIG. 7. Remove the screw and metal strap.
6. Reinstall the cover (30).
3. Pull the fuse away from the board.
4. Install new fuse (F1). Reinstall the strap over the
fuse.
5. Reinstall the cover (30). Restore electrical power to
the system.
Color
Solenoid
Identification
Label
Catalyst
Color
Solenoid
Identification
Label
TI12826a
P
Manual Solenoid Overrides
FIG. 6: Color Change Solenoids
312787G
11
Troubleshooting
Color Change Board Diagnostics
See FIG. 7 and Table 4 to troubleshoot the color change board. Also see the System Electrical Schematic on pages
16 and 17.
16
J8, Pin 1
D33
16
D34
D43
D31
D44
D29
J9, Pin 1
J15, Pin 1
D39
D41
D32
D35
D38
J16, Pin 1
D27
D37
J14, Pin 1
D45
D30
D46
D28
J10, Pin 1
D36
16
16
D9
16
D10
D8
F1
16
J7
J11
FIG. 7: 256172 Color Change Board
12
312787G
Troubleshooting
Table 4: Color Change Board Diagnostics
LED
Connector
and Pin Nos.
Board 1 Signal
Description
Board 2 Signal
Description
Diagnosis
D8
n/a
Board OK
Board OK
Blinks (heartbeat) during normal operation.
D9
n/a
Communication (yellow)
Communication (yellow)
Turns on when board is communicating with ProMix 2KS.
D10
J7
Power
Power
Turns on when power is supplied to the board.
D27
J15, 5 & 6
Color 3
Color 16
D28
J14, 3 & 4
Color 1
Color 14
D29
J8, 5 & 6
Color 6
Color 19
D30
J14, 1 & 2
Color 2
Color 15
D31
J8, 3 & 4
Color 7
Color 20
D32
J16, 3 & 4
Catalyst 4
Color 26
D33
J8, 1 & 2
Color 8
Color 21
D34
J9, 5 & 6
Color 9
Color 22
D35
J15, 3 & 4
Color 4
Color 17
D36
J14, 5 & 6
Solvent (Color)
Color 13
D37
J10, 5 & 6
Catalyst 2
Color 28
D38
J16, 1 & 2
Catalyst 3
Color 27
D39
J16, 5 & 6
Color 12
Color 25
D41
J15, 1 & 2
Color 5
Color 18
D43
J9, 3 & 4
Color 10
Color 23
D44
J9, 1 & 2
Color 11
Color 24
D45
J10, 3 & 4
Catalyst 1
Color 29
D46
J10, 1 & 2
Solvent (Catalyst)
Color 30
D27 through D46 turn on when
ProMix 2KS sends a signal to
actuate the related solenoid
valve.
Replace the Color Change Board
3. Remove the six mounting screws (16) and the board
(15).
4. Install the new board (15). Reinstall the screws (16).
1. Remove electrical power from the system. Remove
the color change module cover (30).
5. Reconnect the cables to the proper connectors, as
noted in step 2.
2. See FIG. 7 on page 12. Note where each cable is
connected, then disconnect all cables from the color
change board connectors (J7, J8, J9, J10, J11, J14,
J15, J16).
6. Reinstall the cover (30). Restore electrical power to
the system.
312787G
13
Schematic Diagrams
Schematic Diagrams
System Pneumatic Diagram
COLOR
CHANGE
CONTROL
A B
SE BE
CLO 2 TU
5/3 N
E
OP
DOSE A
VALVE
12 VDC
4-WAY SOLENOID
A B
SE BE
CLO 2 TU
5/3 N
E
OP
DOSE B
VALVE
12 VDC
05
AIR INPUT
4-WAY SOLENOID
CONTROL AIR
3/8 AIR FILTER
MANUAL DRAIN
5 MICRON
WALL MOUNT ONLY
PURGE AIR
A B
SE BE
CLO 2 TU
5/3 N
E
OP
PURGE A
VALVE
4-WAY SOLENOID
A B
12 VDC
A B
AIR EXHAUST MUFFLER
SE BE
CLO 2 TU
5/3 EN
OP
PURGE B
VALVE
SE BE
CLO 2 TU
5/3 N
E
OP
PURGE C
VALVE
(OPTIONAL)
E
DUMP A
VALVE
(OPTIONAL)
BE
DUMP B
VALVE
(OPTIONAL)
12 VDC
3-WAY SOLENOID
A
UB
2T
5/3 N
E
OP
A
U
2T
5/3 N
E
P
O
AIR INPUT
12 VDC
3-WAY SOLENOID
3-WAY SOLENOID
E
GFB 1
VALVE
(OPTIONAL)
E
GFB 2
VALVE
(OPTIONAL)
A
UB
2T
5/3 N
E
P
O
A
UB
2T
5/3 N
E
OP
12 VDC
3-WAY SOLENOID
COLOR 13
COLOR 14
COLOR 15
COLOR 16
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
COLOR 22
COLOR 23
COLOR 24
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
MAC
36 SERIES SOLENOID VALVES
12 VDC
14
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
COLOR SOLVENT
COLOR 9
COLOR 10
COLOR 11
COLOR 12
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
CATALYST SOLVENT
12 VDC
4-WAY SOLENOID
MANIFOLD
1/4 TUBE
12 VDC
4-WAY SOLENOID
TO MANIFOLD
MANIFOLD
FLUSH AIR TO FLUID INLET
1/4 TUBE
AIR EXHAUST MUFFLER
COLOR
VALVE
STACKS
312787G
Schematic Diagrams
Color Change Module Electrical Schematic
WIRING DIAGRAM
COLOR 8 (21)
COLOR 7 (20)
COLOR 6 (19)
COLOR 5 (18)
COLOR 4 (17)
COLOR 3 (16)
COLOR 2 (15)
COLOR 1 (14)
COLOR FLUSH (13)
312787G
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
J8
J15
J14
J9
J16
J10
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COLOR 9 (22)
COLOR 10 (23)
COLOR 11 (24)
COLOR 12 (25)
CATALYST 4 (26)
CATALYST 3 (27)
CATALYST 2 (28)
CATALYST 1 (29)
CATALYST FLUSH (30)
15
Schematic Diagrams
System Electrical Schematic
Non-Hazardous Area
NON-HAZARDOUS AREA
OPERATOR INTERFACE
DC OK
+24 VDC
COMMON
COMMON
+
+
-
1
2
POWER
SUPPLY
L1
N
L1 85-250 VAC
N
LINE
FILTER
L1
N
GND
1
2
3
POWER HARNESS
BARRIER
BOARD
J1
1
2
3
4
5
J5
1
2
3
J4
1
2
3
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
L1
N
GND
GND LUG
GND N L1
85-250
VAC
1 POWER
2 ROCKER
1A SWITCH
1B
2A
2B
OPEN
OPEN
HARNESS
L1 TERMINAL
N
BLOCK
GND
+12VDC I/S (RED)
COM (BLACK)
SHIELD
CABLE
+24VDC
OPEN
COMMON
(50' STD.)/
(100' OPTION)
ALARM
MEMBRANE
SWITCH
WITH
RIBBON
CABLE
J4
1
2
3
4
5
6
7
8
9
10
11
DISPLAY
BOARD
J9
J6
RJ45
1
2
3
4
+
-
+
-
RJ45
3'
POWER DIST.
TERMINAL
BLOCKS
J2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
+
-
+
-
+
-
+
RJ45
1
2
3
4
J5 5
6
7
8
9
10
J2
J3
REMOTE
I/O
INTEGRATION
BOARD
SHIELD
DISPLAY
-
RJ45
FLOW CONTROL CAL. (BLK)
GUN TRIGGER (WHT)
DIGITAL IN COMMON (RED)
REMOTE STOP (GRN)
ALARM RESET (BRN)
ALARM OUTPUT (BLU)
DIGITAL OUTPUT COMMON (ORG)
POT LIFE (YEL)
FLOW RATE ANALOG IN (PUR)
FLOW RATE ANALOG COMMON (GRAY)
J4
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
1
2
3
4
5
6
7
8
MIX INPUT
PURGE INPUT
JOB COMPLETE INPUT
EXTERNAL CLR CHG READY
RESET ALARM INPUT
DIGITAL INPUT COMMON
DIGITAL INPUT COMMON
RECIPE BIT 0 INPUT
RECIPE BIT 1 INPUT
RECIPE BIT 2 INPUT
RECIPE BIT 3 INPUT
RECIPE BIT 4 INPUT
RECIPE BIT 5 INPUT
RECIPE CHANGE INPUT
1
2
3
4
5
6
7
8
DIGITAL OUTPUT COMMON/POWER
PURGE/RECIPE CHG ACTIVE OUTPUT
MIX ACTIVE OUTPUT
MIX READY OUTPUT
FILL ACTIVE
FLOW CAL. ACTIVE
FLOW RATE ALARM OUTPUT
DIGITAL OUTPUT COMMON/POWER
1
2
3
DIGITAL OUTPUT COMMON/POWER
SPECIAL OUTPUT #1
SPECIAL OUTPUT #2
SPECIAL OUTPUT #3
SPECIAL OUTPUT #4
DIGITAL OUTPUT COMMON/POWER
J5 4
5
6
I/O HARNESSES
J10
1
2
3
4
5
6
RS485 INTEGRATION A (WHT/BLU)
RS485 INTEGRATION B (BLU/WHT)
RS485 INTEGRATION GROUND (SHIELD)
RS485 NETWORK A (WHT/ORG)
RS485 NETWORK B (ORG/WHT)
RS485 NETWORK GROUND (SHIELD)
1
2
3
4
5
6
(+24) YEL
(COM) GRAY
ORG
BRN
RED
TERMINAL
BLOCKS
BEACON
CABLE
J7
J8
P1
RJ45
FO IN (BLK)
FO OUT (BLU)
RJ45
3'
RJ45
BULKHEAD
RJ45
RJ45
3'
(25'-200' OPTIONS)
16
WEB SERVER
MODULE
312787G
Schematic Diagrams
System Electrical Schematic
Hazardous Area
HAZARDOUS AREA
FLUID PANEL CONTROL BOX
FLUID
PANEL
CONTROL
BOARD
J3
J12
J10
1 +12VDC I/S
2 COM
3 SHIELD
J13
J5
MH2
J11
3X CABLE
1
2
3
4
5
6
PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
1
2
3
4
5
6
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
FLOW METER A
FLOW METER SOLVENT
V/P ANALOG OUT (WHT)
PRESS. (GRN)
+12 V (RED)
GND (BLK)
CHASSIS (BARE)
GROUND
TERMINAL
(10')/
(40')
3
2
5
4
1
6' STD.
(3'-100' OPTIONS)
GRD (BLK)
+12VDC (RED)
SHIELD (BARE)
CAN H (WHT)
CAN L (BLU)
3
2
5
4
1
CLR 8
MANIFOLD
CLR 7
3
2
5
4
1
GRD (BLK)
+12VDC (RED)
SHIELD (BARE)
CAN H (WHT)
CAN L (BLU)
CLR 6
BOOTH
CONTROL
BOARD
CLR 5
CLR 4
CLR 3
J14
J9
312787G
FO OUT
(BLU)
J4
FO IN
(BLK)
J6
J1
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
6
5
4
3
2
1
6
5
4
3
2
1
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
1
2
3
4
5
6
7
8
9
10
SIG
COM
SIG
COM
SIG
COM
SIG
COM
SIG
COM
MANIFOLD
CLR 1
DUMP B
GFB #1
GFB #2
DUMP A
MANIFOLD
NOT USED
SOL CLR
PURGE A
NOT USED
NOT USED
DOSE B
DOSE A
AIR FLOW SWITCH 1
AIR FLOW SWITCH 2
1
2
3
4
5
J2
J4
SIG (RED)
COM (BLK)
TECNO
V/P
+ PRESSURE (GRN)
COM (RED)
EX+ (WHT)
- PRESSURE (BLK)
SHIELD (BARE)
FLUID
PRESS.
SENS.
1 4 5 2 3
COLOR
BOARD 1
(COLORS
1 THRU 12,
CATALYST
1 THRU 4)
1
2
3
4
5
6
J8
J9
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
J16
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J7/J11
J14
J10
MANIFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
CLR 12
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
CAT 2
CLR 9
CLR 10
CLR 11
CAT 4
CAT 3
CAT 1
SOL CAT
1 4 5 2 3
6' STD.
J7/J11
PURGE C
PURGE B
1
2
+12VDC
COM
+12VDC
COM
+12VDC
COM
12 VDC
3-WAY SOLENOID
6
5
4
3
2
1
6
5
4
3
2
1
12 VDC
4-WAY SOLENOID
J15
1 FLOW
2 CONTROL
3 BOARD
4
5
J7/J11
CLR 2
J8
J1
1
2
3
4
5
6
50' STD.
J7
I.S. METERS
FLOW METER B
CLR 21
CLR 20
CLR 19
CLR 18
CLR 17
CLR 16
CLR 15
CLR 14
CLR 13
MANIFOLD
+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
1 4 5 2 3
COLOR
BOARD 2
(COLORS
13 THRU 30)
J8
J15
J14
J9
J16
J10
MANIFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
CLR 25
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
CLR 28
CLR 22
CLR 23
CLR 24
CLR 26
CLR 27
CLR 29
CLR 30
SOLVENT FLOW SWITCH
GFB 1 PRESSURE SWITCH
GFB 2 PRESSURE SWITCH
17
Parts
Parts
Low Pressure Color Change Kits
Kit Part
No.
Series
Kit Description
Control Module
(101; see page 20)
Color Valve Stack
(102; see 312783)
Catalyst Valve Stack
(103; see 312783)
256581
2 color
277752
15V812
none
256582
4 color
277753
15V813
none
256583
7 color
277754
15V814
none
256584
12 color
277755
15V815
none
256585
2 color/2 catalyst
277879
15V812
15V812
256586
4 color/2 catalyst
277880
15V813
15V812
256587
4 color/4 catalyst
277881
15V813
15V813
7 color/2 catalyst
277882
15V814
15V812
256589
7 color/4 catalyst
277883
15V814
15V813
256590
12 color/2 catalyst
277884
15V815
15V812
256591
12 color/4 catalyst
277885
15V815
15V813
256592
13-18 color
278113
256293
none
256593
13-24 color
278114
15V815
none
256594
13-30 color
277885
256305
none
256595
1 catalyst/1 flush
278095
none
256994
Control Module
(101; see page 20)
Color Valve Stack
(102; see 312783)
Catalyst Valve Stack
(103; see 312783)
256588
A
High Pressure Color Change Kits
Kit Part
No.
Series
Description
256596
2 color
277752
15V816
none
256597
4 color
277753
15V817
none
256598
7 color
277754
256343
none
256599
12 color
277755
256348
none
256600
2 color/2 catalyst
277879
15V816
15V816
256601
4 color/2 catalyst
277880
15V817
15V816
256602
4 color/4 catalyst
277881
15V817
15V817
7 color/2 catalyst
277882
256343
15V816
256604
7 color/4 catalyst
277883
256343
15V817
256605
12 color/2 catalyst
277884
256348
15V816
256606
12 color/4 catalyst
277885
256348
15V817
256607
13-18 color
278113
256342
none
256608
13-24 color
278114
256348
none
256609
13-30 color
277885
256354
none
256610
1 catalyst/1 flush
278095
none
256995
256603
18
A
312787G
Parts
Color Change Kits Parts
101
Screw Location
(item 32)
30
11
11
103
13
102
19
TI12828b
17
20
20
TI12829a
312787G
19
Parts
Color Change Control Modules
(Ref. No. 101; see page 18)
Ref.
No.
Part No.
1
2
3
4
5
6
7
8
9
10
11
13
14
17
18
19
20
Description
277752
278095
15T636
114669
121324
121628
112698
121487
109193
100139
15V821
598095
590332
119162
15U927
C06061
24N345
C19798
Qty
MODULE, control, color change; see page 22
MODULE, control, 1 catalyst/1 flush change; see page 23
MANIFOLD, color change control
SCREW, machine, phillips pan hd; M5 x 10 mm (behind panel 12 and manifold 2)
VALVE, solenoid
SCREW, self-sealing; 4-40 x 1/4 in. (6 mm)
ELBOW, tube; 1/8 npt(m) x 1/4 in. (6 mm) OD tube
GROMMET
ELBOW, tube; 10-32 x 5/32 in. (4 mm) OD tube
PLUG, pipe; 1/8 -27 npt
KIT, dump valve; see 312786
TUBE; 5/32 in. (4 mm) OD; nylon; see page 19
TUBE; 1/4 in. (6 mm) OD
CONNECTOR, plug, 6 position
BRACKET, color change; see page 19
MUFFLER
HOSE; ptfe; 1/4 npsm(fbe); 1/4 in. (6 mm) ID; 1.5 ft (0.46 m); see page 19
SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm); see page 19
See
Table
Below
Control Module Part Quantities
Ref. Nos.
Module
No.
1
277753
277754
277755
277879
277756‡
277880
277757‡
277882
277758‡
277884
277759‡
277881
277771‡
277883
277772‡
277885
277773‡
278113
278114
*
20
2
3
4
5
6
7
8
9
10
1
1
1
1
0
0
1
1
0
0
2
2
2
5
10
3
0
0
0
12
0
0
1
1
0
0
1
1
2
5
10
3
0
0
2
2
1
1
2
5
8
1
1
5
2
1
1
2
8
10
1
1
8
2
1
1
2
13
0
1
1
13
2
1
1
2
7
4
1
1
7
2
1
1
2
10
0
1
1
10
2
1
1
2
15
0
1
1
15
2
1
1
0
1
0
2
3
9
0
0
0
1
0
1
3
9
0
2
Quantities for ref. nos. 11 and 13 are in feet (meters).
0
0
0
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
0
11*
13*
14
17
18
19
10 (3)
25 (7.6)
50 (15.2)
15 (4.6)
0
0
0.7 (0.2)
0.7 (0.2)
1
2
3
1
0
0
0
1
0
0
1
1
0
0
0
1
25 (7.6)
0.7 (0.2)
2
1
1
1
40 (12.2)
0.7 (0.2)
3
1
1
1
65 (19.8)
0.7 (0.2)
4
1
1
1
35 (10.7)
0.7 (0.2)
2
1
1
1
50 (15.2)
0.7 (0.2)
3
1
1
1
75 (22.9)
0.7 (0.2)
4
1
1
1
15 (4.6)
45 (13.7)
0
0.7 (0.2)
1
3
0
1
0
1
0
0
‡ These modules include two dump valve kits (10).
312787G
Parts
13
6
9
2
5
14
4
9
18
7
8
TI12826a
312787G
21
Parts
277752 2-Color Control Module
Ref.
No.
2
3
4
5
7
8
9
11
12
13
14
15
16
17
18
19
20
26
29
30
31
32
Part No.
Description
15T636
103833
121324
121628
121487
109193
100139
598095
15T635
590332
119162
256172
112324
15U927
C06061
24N345
C19798
116343
115671
15T752
123690
n/a
Qty
1
2
3
12
1
3
2
1
1
1
1
1
6
1
1
1
4
1
1
1
1
4
MANIFOLD, color change control
SCREW, machine, pan hd; 10-32 x 3/8 in. (10 mm) (behind panel 12 and manifold 2)
VALVE, solenoid
SCREW, self-sealing; 4-40 x 1/4 in. (6 mm)
GROMMET
ELBOW, tube; 10-32 x 5/32 in. (4 mm) OD tube
PLUG, pipe; 1/8 -27 npt
TUBE; 5/32 in. (4 mm) OD; 15 ft (4.6 m); nylon; see page 19
PANEL
TUBE; 1/4 in. (6 mm) OD; 5 ft (1.5 m); see page 19
CONNECTOR, plug, 6 position
BOARD, circuit
SCREW, machine, pan-hd, 4-40 x 1/4 in. (6 mm)
BRACKET, color change; see page 19
MUFFLER
HOSE; ptfe; 1/4 npsm(fbe); 1/4 in. (6 mm) ID; 1.5 ft (0.46 m); see page 19
SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm); see page 19
SCREW, ground
FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube
COVER, color change control; see page 19
FUSE; 125 mA
SCREW, machine, serrated hex-head (see page 19)
Parts labeled n/a are not available separately.
9
15
12
2
5
14
16
31
1
8
22
7
18
29
4
26
1
Replacing the fuse with a non-Graco fuse
voids the IS system safety approval.
TI12824a
312787G
Parts
278095 1 Catalyst/1 Flush Control Module (0 Color)
Ref.
No.
Part No.
2
3
4
5
7
8
9
11
12
13
14
15
16
17
18
19
20
26
29
30
31
32
15T636
103833
121324
121628
121487
109193
100139
598095
15T635
590332
119162
256172
112324
15U927
C06061
24N345
C19798
116343
115671
15T752
123690
n/a
Description
Qty
1
2
2
14
1
2
2
1
1
1
1
1
6
1
1
1
4
1
1
1
1
4
MANIFOLD, color change control
SCREW, machine, pan hd; 10-32 x 3/8 in. (10 mm) (behind panel 12 and manifold 2)
VALVE, solenoid
SCREW, self-sealing; 4-40 x 1/4 in. (6 mm)
GROMMET
ELBOW, tube; 10-32 x 5/32 in. (4 mm) OD tube
PLUG, pipe; 1/8 -27 npt
TUBE; 5/32 in. (4 mm) OD; 15 ft (4.6 m); nylon; see page 19
PANEL
TUBE; 1/4 in. (6 mm) OD; 5 ft (1.5 m); see page 19
CONNECTOR, plug, 6 position
BOARD, circuit
SCREW, machine, pan-hd, 4-40 x 1/4 in. (6 mm)
BRACKET, color change; see page 19
MUFFLER
HOSE; ptfe; 1/4 npsm(fbe); 1/4 in. (6 mm) ID; 1.5 ft (0.46 m); see page 19
SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm); see page 19
SCREW, ground
FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube
COVER, color change control; see page 19
FUSE; 125 mA
SCREW, machine, serrated hex-head (see page 19)
Parts labeled n/a are not available separately.
15
9
12
2
5
14
1
1
312787G
31
Replacing the fuse with a non-Graco fuse
voids the IS system safety approval.
16
TI13546a
26
4
29
18
7
8
23
Dimensions
Dimensions
16.57 in. (420.9 mm)
4.52 in.
(114.8 mm)
15.07 in. (382.8 mm)
8.71 in.
(221.2 mm)
5.31 in.
(134.9 mm)
TI12824a
24
TI12825b
312787G
Technical Data
Technical Data
Air Specifications
Maximum Air Input Pressure . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar)
Minimum Air Input Pressure. . . . . . . . . . . . . . . . . . . . 75 psi (0.52 MPa, 5.2 bar)
Fluid Specifications
Maximum Fluid Working Pressure . . . . . . . . . . . . . . . Low Pressure Valve Stacks: 300 psi (2.1 MPa, 21 bar)
High Pressure Valve Stacks: 3000 psi (21 MPa, 210 bar)
Fluid Wetted Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 SST, Tungsten Carbide, ptfe
Hose: ptfe
Color Change Valves: see manual 312782
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see table below
Control Module
Weight, lb (kg)
Control Module
Weight, lb (kg)
2 color
6.10 (2.77)
7 color/2 catalyst
7.55 (3.42)
4 color
6.50 (2.95)
7 color/4 catalyst
7.95 (3.61)
7 color
7.10 (3.22)
12 color/2 catalyst
8.30 (3.76)
12 color
7.95 (3.61)
12 color/4 catalyst
8.70 (3.95)
2 color/2 catalyst
6.55 (2.97)
4 color/2 catalyst
6.95 (3.15)
4 color/4 catalyst
7.35 (3.33)
312787G
25
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 312787
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS, MN 55440-1441 • USA
Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised September 2012