color change module kits€¦ · table 2: color change board switch settings for promix 2ks systems...

312787HEN

Instructions-Parts

Color Change Module Kits

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 InstructionsRead 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 instruc-tions.

TI12828b

Color Change Kit shown installed in a ProMix 2KS Proportioning System

Related Manuals

2 312787H

ContentsRelated Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Low Pressure Kits . . . . . . . . . . . . . . . . . . . . . . . . 3High Pressure Kits . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Install Color Change Control Module . . . . . . . . . 4Install Color Valve Stacks . . . . . . . . . . . . . . . . . . 7Connect Valve Air Lines . . . . . . . . . . . . . . . . . . . 7Connect Valve Fluid Lines . . . . . . . . . . . . . . . . . 7Color Change Board Switch Settings . . . . . . . . . 7Accessory Dump Valve Kit . . . . . . . . . . . . . . . . . 7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 10Color Change Solenoid Valves . . . . . . . . . . . . . 10Color Change Board Fuse . . . . . . . . . . . . . . . . 10Replace a Solenoid . . . . . . . . . . . . . . . . . . . . . . 11Replace the Color Change Board Fuse . . . . . . 11Color Change Board Diagnostics . . . . . . . . . . . 12Replace the Color Change Board . . . . . . . . . . . 13

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 14System Pneumatic Diagram . . . . . . . . . . . . . . . 14Color Change Module Electrical Schematic . . . 15System Electrical Schematic . . . . . . . . . . . . . . . 16

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Low Pressure Color Change Kits . . . . . . . . . . . 18High Pressure Color Change Kits . . . . . . . . . . . 18Color Change Control Modules . . . . . . . . . . . . . 20277752 2-Color Control Module . . . . . . . . . . . . 22278095 1 Catalyst/1 Flush Control Module

(0 Color) . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 26

Related ManualsSee 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 Installa-tion

312779 ProMix 2KS Automatic System Opera-tion

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 Opera-tion

312782 Dispense Valve

312783 Color and Catalyst Change Valve Stacks

312786 Dump Valve and Third Purge Valve Kits

Models

312787H 3

Models

Low Pressure Kits100 psi (0.7 MPa, 7.0 bar) Maximum Air Inlet Pressure

300 psi (2.1 MPa, 21 bar) Maximum Fluid Working Pressure

High Pressure Kits100 psi (0.7 MPa, 7.0 bar) Maximum Air Inlet Pressure

3000 psi (21 MPa, 210 bar) Maximum Fluid Working Pressure

Kit Part No. Series Description

256581

A

2 color

256582 4 color

256583 7 color

256584 12 color

256585 2 color/2 catalyst







256592 13-18 color

256593 13-24 color

256594 13-30 color

256595 1 catalyst/1 flush (0 color)


256596

A

2 color

256597 4 color

256598 7 color

256599 12 color








256607 13-18 color

256608 13-24 color

256609 13-30 color

256610 1 catalyst/1 flush (0 color)

Installation

4 312787H

Installation

Install Color Change Control Module

Location

Install the color change control module (101) near the fluid station. The module is approved for use in a haz-ardous location. Also see your system installation man-ual. 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 equip-ment, fluid, hoses, and stress caused during opera-tion.

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 accessi-ble for maintenance.

4. Drill mounting holes in the wall. Install anchors as needed.

5. Bolt equipment securely.

• 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.

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.

FIG. 1: Control Module Installation

TI12828b

101

11

SV

EC

11

SV

13

FSLFSL

Installation

312787H 5

Connect Module to Fluid Station Board

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

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 con-nect the color change control module and fluid station. Recommended length is 3 ft (1.0 m) or 6 ft (2.0 m).

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.

Connect Air Supply to Control Module

Connect a 1/4 in. (6 mm) OD tube (13) between the sys-tem’s air manifold (at the bottom rear of the fluid station) and the module air inlet fitting (29). See FIG. 3.

The air supply must be clean and dry. Use a 5 micron fil-ter. Regulate the air pressure to 75-100 psi (0.52-0.70 MPa, 5.25-7.0 bar).

NOTICETo avoid damaging circuit board when servicing, wear grounding strap on wrist and ground appropriately.

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)

15V207 15 (5.0)

15V208 25 (8.0)

15U533 50 (16.0)

15V213 100 (32.0)

FIG. 2: Fluid Station Control Board Connection

J11(Color Change Module)

FIG. 3: Solenoid Air Connection

TI12824a29

Installation

6 312787H

Installation

312787H 7

Install Color Valve Stacks1. Install the bracket (17) on the fluid station (FS) with

two screws (20). See FIG. 4.

2. Install the color or catalyst valve stack (VS) to the bracket (17) with two screws (20).

Connect Valve Air LinesSee 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.

NOTE: The high pressure color change valves use a spring-operated exhaust which does not require a sec-ond air line.

Connect Valve Fluid Lines1. 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,

2. Connect the hose (19) from the manifold stack fluid outlet (F) to the flow meter inlet (M). FIG. 4.

Color Change Board Switch SettingsSet 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.

FIG. 4: Install Valve Stacks

TI12829a

1720

FS

VS

20

FM

NOTICEVerify that all unused fluid ports on the color change valve stack are plugged before operation. An open port will leak fluid.

NOTICEA check valve is recommended on all dead head valves to prevent color crossover if two valves are open at the same time.

Installation

8 312787H

Table 2: Color Change Board Switch Settings for ProMix 2KS Systems

Two Color Change Boards

Color Change Board 1 Color Change Board 2

Effect on System

S3 S6 S5 S4 S3 S6 S5 S4

TerminationResistor Board ID

Catalyst On/Off

Color On/Off


Catalyst On/Off

Color On/Off

OFF ON ON ON ON OFFNOT USED

4 catalyst/30 color valves

OFF ON OFF ON ON OFF 0 catalyst/30 color valves

One Color Change Board

ON ON ON ON

NOT PRESENT

4 catalyst/12 color valves

ON ON ON OFF 4 catalyst/0 color valves

ON ON OFF ON 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

Effect on System

S3 S6 S5 S4 S3 S6 S5 S4


Catalyst On/Off

Color On/Off


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 com-ponent C valves, 25 color valves

OFF ON OFF ON ON OFF ON ON 4 component C valves, 25 color valves

One Color Change Board

ON ON ON ON

NOT PRESENT

4 catalyst valves, 12 color valves

ON ON ON OFF 4 catalyst valves, 0 color valves

ON ON OFF ON 0 catalyst valves, 12 color valves

Installation

312787H 9

FIG. 5. 256172 Color Change Board Switch Settings

OFF

ON

OFF

ON

S3

S4

S5

S6

J7 J11

Switch S3-S6

TI13661a

Troubleshooting

10 312787H

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.

Color Change Board Fuse

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 dam-aged or connections loose.

Visually inspect air and electrical lines for kinks, damage, or loose connec-tions. 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 function-ing 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).

Problem Cause Solution

No power to board. Communication between color change module and fluid station is interrupted.

Color change board fuse (F1) is blown.

Verify condition of fuse. Replace if necessary. See page 11.

Troubleshooting

312787H 11

Replace a Solenoid1. 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.

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 Mod-ule Electrical Schematic on page 15 and the Sys-tem Electrical Schematic on page 17.

6. Reinstall the cover (30).

Replace the Color Change Board Fuse

NOTE: Replacing the fuse with a non-Graco fuse voids the IS system safety approval.

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.

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.

Fuse Part No. Description

F1 123690 Fuse; 125 mA, intrinsically safe

FIG. 6: Color Change Solenoids

TI12826a

Manual Solenoid Overrides

Solenoid Identification Label

SolenoidIdentification

Label

Col

or

Color

Catalyst

P

Troubleshooting

12 312787H

Color Change Board DiagnosticsSee FIG. 7 and Table 4 to troubleshoot the color change board. Also see the System Electrical Schematic on pages 16 and 17.

FIG. 7: 256172 Color Change Board

J8, Pin 1

J9, Pin 1

J14, Pin 1

J15, Pin 1

D45

D36

D46

D37

D44

D8

D29

D41

D35

D31

D9

J16, Pin 1

J10, Pin 1

D34

D43

D39

D32

D38

D28

D30

D27

D33

D10

J7 J11

F1

16

16

16

16

16

16

Troubleshooting

312787H 13

Replace the Color Change Board

1. Remove electrical power from the system. Remove the color change module cover (30).

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).

3. Remove the six mounting screws (16) and the board (15).

4. Install the new board (15). Reinstall the screws (16).

5. Reconnect the cables to the proper connectors, as noted in step 2.

6. Reinstall the cover (30). Restore electrical power to the system.

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 nor-mal operation.

D9 n/a Communication (yellow) Communication (yellow) Turns on when board is com-municating with ProMix 2KS.

D10 J7 Power Power Turns on when power is sup-plied to the board.

D27 J15, 5 & 6 Color 3 Color 16

D27 through D46 turn on when ProMix 2KS sends a signal to actuate the related solenoid valve.

D28 J14, 3 & 4 Color 1 Color 14

D29 J8, 5 & 6 Color 6 Color 19

D30 J14, 1 & 2 Color 2 Color 15


D32 J16, 3 & 4 Catalyst 4 Color 26



D35 J15, 3 & 4 Color 4 Color 17

D36 J14, 5 & 6 Solvent (Color) Color 13



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


D46 J10, 1 & 2 Solvent (Catalyst) Color 30

Schematic Diagrams

14 312787H

Schematic Diagrams

System Pneumatic Diagram

3/8 AIR FILTERMANUAL DRAIN5 MICRONWALL MOUNT ONLY

FLUS

H AI

R TO

FLUI

D IN

LET

1/4 T

UBE

TO M

ANIFO

LD

1/4 T

UBE

4-WAY SOLENOID

12 VDC

PURGE AVALVE

DUMP AVALVE(OPTIONAL)

4-WAY SOLENOID

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

12 VDC

MANIFOLDAIR EXHAUST MUFFLER

OPEN

CLOSE

OPEN5/32 TUBE

5/32 TUBE

PURGE BVALVE

4-WAY SOLENOID

12 VDC

CLOSE

OPEN5/32 TUBE

DUMP BVALVE(OPTIONAL)

4-WAY SOLENOID

12 VDC

OPEN5/32 TUBE

A B

A B

A B

A B

A

A

DOSE AVALVECLOSE

OPEN5/32 TUBE

DOSE BVALVECLOSE

OPEN5/32 TUBE

3-WAY SOLENOID

12 VDCGFB 1VALVE(OPTIONAL)5/32 TUBE

A

COLOR 1COLOR 2COLOR 3COLOR 4COLOR 5COLOR 6COLOR 7COLOR 8COLOR SOLVENTCOLOR 9COLOR 10COLOR 11COLOR 12CATALYST 1CATALYST 2CATALYST 3CATALYST 4CATALYST SOLVENT

COLORCHANGECONTROL

COLORVALVESTACKS

MAC36 SERIES SOLENOID VALVES

05

COLOR 13COLOR 14COLOR 15COLOR 16COLOR 17COLOR 18COLOR 19COLOR 20COLOR 21COLOR 22COLOR 23COLOR 24COLOR 25COLOR 26COLOR 27COLOR 28COLOR 29COLOR 30

PURGE CVALVE(OPTIONAL)4-WAY SOLENOID

12 VDC

CLOSE

OPEN5/32 TUBE

A B

AIR EXHAUST MUFFLER

3-WAY SOLENOID

12 VDCGFB 2VALVE(OPTIONAL)

OPEN5/32 TUBE

A

OPEN

MANIFOLD

AIR INPUT

AIR INPUT

PU

RG

E A

IR

CO

NT

RO

L A

IR

Schematic Diagrams

312787H 15

Color Change Module Electrical Schematic

WIRING DIAGRAM

COM+12VDCCOM+12VDC COM+12VDC COM+12VDC COM+12VDC COM+12VDC COM+12VDC COM+12VDC COM+12VDC

J8

J15

J14

J9

J16

J10

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)

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)

+12VDCCOM+12VDCCOM+12VDCCOM



Schematic Diagrams

16 312787H

System Electrical Schematic

Non-Hazardous Area

BARRIERBOARD

OPERATOR INTERFACE

12

L1N

85-250 VAC

GND N L1

85-250 VAC

123

J5+12VDC I/S (RED)COM (BLACK)SHIELD

123

J4+24VDCOPENCOMMON

DISPLAYBOARD

NON-HAZARDOUS AREA

1234

J9 +-

FO IN (BLK)FO OUT (BLU)

1234567891011

J4

1234567891011121314151617181920

DISPLAY

MEMBRANESWITCHWITHRIBBONCABLE

CABLE

HARNESS

TERMINALBLOCK

123

GND LUG

121A1B2A2B

POWERROCKERSWITCH1

2345

J1

OPEN OPEN

ALARM

CABLE

(50' STD.)/

(100' OPTION)

123456

J10

12345678910

J5

J7J8

RJ45MIX INPUTPURGE INPUTJOB COMPLETE INPUTEXTERNAL CLR CHG READYRESET ALARM INPUTDIGITAL INPUT COMMON

123456

RJ45

POWERSUPPLY

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)

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)

12345678

DIGITAL INPUT COMMONRECIPE BIT 0 INPUTRECIPE BIT 1 INPUTRECIPE BIT 2 INPUTRECIPE BIT 3 INPUTRECIPE BIT 4 INPUTRECIPE BIT 5 INPUTRECIPE CHANGE INPUT

12345678

DIGITAL OUTPUT COMMON/POWERPURGE/RECIPE CHG ACTIVE OUTPUTMIX ACTIVE OUTPUTMIX READY OUTPUTFILL ACTIVEFLOW CAL. ACTIVEFLOW RATE ALARM OUTPUTDIGITAL OUTPUT COMMON/POWER

DIGITAL OUTPUT COMMON/POWERSPECIAL OUTPUT #1SPECIAL OUTPUT #2SPECIAL OUTPUT #3SPECIAL OUTPUT #4DIGITAL OUTPUT COMMON/POWER

123456

REMOTEI/O INTEGRATIONBOARD

J2

J3

J4

J5

RJ45RJ45P1

J6

WEB SERVERMODULE

RJ45

RJ45

RJ45RJ45

TERMINAL BLOCKS

++--

DC OK

COMMON

+24 VDCCOMMON

+-

J2

SHIEL

D

+

+

+

+

-

-

-

-

POWER DIST. TERMINAL BLOCKS

3'

3'(25'-200' OPTIONS)

12345678910

123456

RJ45BULKHEAD

3'

I/O HARNESSES

POWER HARNESS

BEACON(+24) YEL

(COM) GRAY ORG BRN RED

UNUSEDUNUSEDUNUSEDUNUSEDUNUSED

L1 NGND

L1N

LINEFILTER

L1NGND

L1 NGND

Schematic Diagrams

312787H 17

System Electrical Schematic

Hazardous Area

HAZARDOUS AREA

+12VDC I/SCOMSHIELD

J10123

123456

J3

PWR (RED)COM (BLACK)SIG (WHITE)SHIELD/GRNPWR (RED)COM (BLACK)SIG (WHITE)SHIELD/GRNPWR (RED)COM (BLACK)SIG (WHITE)SHIELD/GRN

FLUIDPANELCONTROLBOARD

FLUID PANEL CONTROL BOX

FLOW METER A

FLOW METER B

123456

J5

12345

FLOWCONTROLBOARD

654321

J9

BLACKREDBLACKREDBLACKRED

MANIFOLD

NOT USED

DOSE B

DOSE A

12345678910

J1

SIGCOMSIGCOMSIGCOMSIGCOMSIGCOM

AIR FLOW SWITCH 1

FO OUT (BLU)

FO IN(BLK)

12

J1J2

3X CABLE

FLOW METER SOLVENT

12345

TECNOV/P

FLUIDPRESS.SENS.

J4

SIG (RED)COM (BLK)

+ PRESSURE (GRN)COM (RED)EX+ (WHT)- PRESSURE (BLK)SHIELD (BARE)

32541

J11GRD (BLK)+12VDC (RED)SHIELD (BARE)CAN H (WHT)CAN L (BLU)

J7/J111 4 5 2 3

COLORBOARD 1(COLORS1 THRU 12, CATALYST1 THRU 4)

CLR 9

CLR 10

CLR 11

1 4 5 2 3

V/P ANALOG OUT (WHT)PRESS. (GRN)+12 V (RED)GND (BLK)CHASSIS (BARE)

MH2

(10')/(40')

6' STD.

6' STD.(3'-100' OPTIONS)

I.S. METERS

32541

GRD (BLK)+12VDC (RED)SHIELD (BARE)CAN H (WHT)

CAN L (BLU)

32541

BOOTHCONTROLBOARD

654321

J14


AIR FLOW SWITCH 2

SOLVENT FLOW SWITCH

GFB 1 PRESSURE SWITCH

GFB 2 PRESSURE SWITCH

PURGE B

PURGE A

NOT USED

654321


DUMP A

NOT USED

PURGE C

MANIFOLD654321


DUMP B

GFB #1

GFB #2

12

VDC

3-W

AY SO

LENO

ID

J15

J8

12

VDC

4-W

AY SO

LENO

ID

123456

J12

J13

123456

UNUSEDUNUSEDUNUSEDUNUSEDUNUSEDUNUSED

GROUNDTERMINAL

50' STD.

123456

+12VDC COM

+12VDC COM

+12VDC COM

MANIFOLD

123456

+12VDC COM

+12VDC COM

+12VDC COM

123456

+12VDC COM

+12VDC COM

+12VDC COM

1 4 5 2 3

MANIFOLD654321

COM+12VDC

COM+12VDC

COM+12VDC

COM

+12VDC COM

+12VDC COM

+12VDC

COM+12VDC

COM+12VDC

COM+12VDC

654321

654321

CLR 12

CAT 4

CAT 3

CAT 2

CAT 1

SOL CAT

CLR 8

CLR 7

CLR 6

CLR 5

CLR 4

CLR 3

CLR 2

CLR 1

SOL CLR

COLORBOARD 2(COLORS13 THRU 30)

CLR 22

CLR 23

CLR 24

123456

+12VDC COM

+12VDC COM

+12VDC COM

MANIFOLD

123456

+12VDC COM

+12VDC COM

+12VDC COM

123456

+12VDC COM

+12VDC COM

+12VDC COM

MANIFOLD654321

COM+12VDC

COM+12VDC

COM+12VDC

COM

+12VDC COM

+12VDC COM

+12VDC

COM+12VDC

COM+12VDC

COM+12VDC

654321

654321

CLR 25

CLR 26

CLR 27

CLR 28

CLR 29

CLR 30

CLR 21

CLR 20

CLR 19

CLR 18

CLR 17

CLR 16

CLR 15

CLR 14

CLR 13

J8

J8

J15

J15

J14

J14

J9

J9

J16

J10

J10

J16

J4

J6

J7

J7/J11

J7/J11

Parts

18 312787H

Parts

Low Pressure Color Change Kits

High 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

A

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







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)

256596

A

2 color 277752 15V816 none

256597 4 color 277753 15V817 none

256598 7 color 277754 256343 none

256599 12 color 277755 256348 none




256603 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

Parts

312787H 19

Color Change Kits Parts

TI12828b

101

102

103

TI12829a

1720

20

11

13

11

19

30

Screw Location (item 32)

Parts

20 312787H

Color Change Control Modules (Ref. No. 101; see page 18)

Control Module Part Quantities

* Quantities for ref. nos. 11 and 13 are in feet (meters). ‡ These modules include two dump valve kits (10).

Ref. No. Part No. Description Qty

1 277752 MODULE, control, color change; see page 22

SeeTableBelow

278095 MODULE, control, 1 catalyst/1 flush change; see page 232 15T636 MANIFOLD, color change control3 114669 SCREW, machine, phillips pan hd; M5 x 10 mm (behind panel 12 and manifold 2)4 121324 VALVE, solenoid5 121628 SCREW, self-sealing; 4-40 x 1/4 in. (6 mm)6 112698 ELBOW, tube; 1/8 npt(m) x 1/4 in. (6 mm) OD tube7 121487 GROMMET8 109193 ELBOW, tube; 10-32 x 5/32 in. (4 mm) OD tube9 100139 PLUG, pipe; 1/8 -27 npt10 15V821 KIT, dump valve; see 31278611 598095 TUBE; 5/32 in. (4 mm) OD; nylon; see page 1913 590332 TUBE; 1/4 in. (6 mm) OD14 119162 CONNECTOR, plug, 6 position17 15U927 BRACKET, color change; see page 1918 C06061 MUFFLER19 24N345 HOSE; ptfe; 1/4 npsm(fbe); 1/4 in. (6 mm) ID; 1.5 ft (0.46 m); see page 1920 C19798 SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm); see page 19

Module No.

Ref. Nos.

1 2 3 4 5 6 7 8 9 10 11* 13* 14 17 18 19

277753 1 0 0 2 0 0 0 2 0 0 10 (3) 0 1 0 0 0277754 1 0 0 5 0 0 0 5 0 0 25 (7.6) 0 2 0 0 0

277755 1 1 2 10 0 1 1 10 2 0 50 (15.2) 0.7 (0.2) 3 0 1 0

277879277756‡

1 1 2 3 12 1 1 3 2 02

15 (4.6) 0.7 (0.2) 1 1 1 1

277880277757‡

1 1 2 5 8 1 1 5 2 02

25 (7.6) 0.7 (0.2) 2 1 1 1

277882277758‡

1 1 2 8 10 1 1 8 2 02

40 (12.2) 0.7 (0.2) 3 1 1 1

277884277759‡

1 1 2 13 0 1 1 13 2 02

65 (19.8) 0.7 (0.2) 4 1 1 1

277881277771‡

1 1 2 7 4 1 1 7 2 02

35 (10.7) 0.7 (0.2) 2 1 1 1

277883277772‡

1 1 2 10 0 1 1 10 2 02

50 (15.2) 0.7 (0.2) 3 1 1 1

277885277773‡

1 1 2 15 0 1 1 15 2 02

75 (22.9) 0.7 (0.2) 4 1 1 1

278113 1 0 0 3 0 0 0 3 0 0 15 (4.6) 0 1 0 0 0

278114 1 1 2 9 0 1 1 9 2 0 45 (13.7) 0.7 (0.2) 3 1 1 0

Parts

312787H 21

TI12826a

2

4

5

7 89

14

18

613 9

Parts

22 312787H

277752 2-Color Control Module

Parts labeled n/a are not available separately.


2 15T636 MANIFOLD, color change control 1

3 103833 SCREW, machine, pan hd; 10-32 x 3/8 in. (10 mm) (behind panel 12 and manifold 2) 2

4 121324 VALVE, solenoid 3

5 121628 SCREW, self-sealing; 4-40 x 1/4 in. (6 mm) 12

7 121487 GROMMET 1

8 109193 ELBOW, tube; 10-32 x 5/32 in. (4 mm) OD tube 3

9 100139 PLUG, pipe; 1/8 -27 npt 2

11 598095 TUBE; 5/32 in. (4 mm) OD; 15 ft (4.6 m); nylon; see page 19 1

12 15T635 PANEL 1

13 590332 TUBE; 1/4 in. (6 mm) OD; 5 ft (1.5 m); see page 19 1

14 119162 CONNECTOR, plug, 6 position 1

15 256172 BOARD, circuit 1

16 112324 SCREW, machine, pan-hd, 4-40 x 1/4 in. (6 mm) 6

17 15U927 BRACKET, color change; see page 19 1

18 C06061 MUFFLER 1

19 24N345 HOSE; ptfe; 1/4 npsm(fbe); 1/4 in. (6 mm) ID; 1.5 ft (0.46 m); see page 19 1

20 C19798 SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm); see page 19 4

26 116343 SCREW, ground 1

29 115671 FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube 1

30 15T752 COVER, color change control; see page 19 1

31 123690 FUSE; 125 mA 1

32 n/a SCREW, machine, serrated hex-head (see page 19) 4

TI12824a

2

4

5

78

9 12

14

15

16

18 29 26

31 1

Replacing the fuse with a non-Graco fuse voids the IS system safety approval.

1

Parts

312787H 23

278095 1 Catalyst/1 Flush Control Module (0 Color)

Parts labeled n/a are not available separately.


2 15T636 MANIFOLD, color change control 1

3 103833 SCREW, machine, pan hd; 10-32 x 3/8 in. (10 mm) (behind panel 12 and manifold 2) 2

4 121324 VALVE, solenoid 2

5 121628 SCREW, self-sealing; 4-40 x 1/4 in. (6 mm) 14

7 121487 GROMMET 1

8 109193 ELBOW, tube; 10-32 x 5/32 in. (4 mm) OD tube 2

9 100139 PLUG, pipe; 1/8 -27 npt 2

11 598095 TUBE; 5/32 in. (4 mm) OD; 15 ft (4.6 m); nylon; see page 19 1

12 15T635 PANEL 1

13 590332 TUBE; 1/4 in. (6 mm) OD; 5 ft (1.5 m); see page 19 1

14 119162 CONNECTOR, plug, 6 position 1

15 256172 BOARD, circuit 1

16 112324 SCREW, machine, pan-hd, 4-40 x 1/4 in. (6 mm) 6

17 15U927 BRACKET, color change; see page 19 1

18 C06061 MUFFLER 1

19 24N345 HOSE; ptfe; 1/4 npsm(fbe); 1/4 in. (6 mm) ID; 1.5 ft (0.46 m); see page 19 1

20 C19798 SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm); see page 19 4

26 116343 SCREW, ground 1

29 115671 FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube 1

30 15T752 COVER, color change control; see page 19 1

31 123690 FUSE; 125 mA 1

32 n/a SCREW, machine, serrated hex-head (see page 19) 4

TI13546a

2

4

5

7 8

9 12

14

15

16

182926

311

Replacing the fuse with a non-Graco fuse voids the IS system safety approval.

1

Dimensions

24 312787H

Dimensions

TI12824a TI12825b

16.57 in. (420.9 mm)

15.07 in. (382.8 mm)

4.52 in. (114.8 mm)

5.31 in. (134.9 mm)

8.71 in. (221.2 mm)

Technical Data

312787H 25

Technical Data

Air SpecificationsMaximum Air Input Pressure . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar)Minimum Air Input Pressure. . . . . . . . . . . . . . . . . . . . 75 psi (0.52 MPa, 5.2 bar)

Fluid SpecificationsMaximum 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: ptfeColor Change Valves: see manual 312782

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see table below

Control Module Weight, lb (kg)

2 color 6.10 (2.77)

4 color 6.50 (2.95)

7 color 7.10 (3.22)

12 color 7.95 (3.61)

2 color/2 catalyst 6.55 (2.97)







Control Module Weight, lb (kg)

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: MinneapolisInternational 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

Revision H, 2018-12

Graco Standard WarrantyGraco 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 CUSTOMERSThe 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

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