Download Graco 312787G User's Manual
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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