Instructions/Parts
Color Change and Remote Mix
Manifold Kits
333282B
EN
To add optional color change function and at-the-gun mixing of two component materials when used
with a ProMix™ PD2K Proportioner for Automatic Spray Applications. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual and in your system
installation, operation, and repair/parts manuals.
Save these instructions.
See page 3 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.
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Related Manuals
Manual No.
332458
Description
Manual No.
332709
Description
PD2K Proportioner, Installation
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Pump Repair-Parts Manual
332454
Color Change Valve Repair-Parts
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332564
332565
PD2K Proportioner Operation
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332456
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Models
Non-Intrinsically Safe Modules
These kits are installed in the non-hazardous location, near the pumps. See the Kit label for the product
part number. See the module identification label for maximum air working pressure, approval information
and certification.
Non-Intrinsically Safe Color Change Control Module Label
Kit Identification Label
Kit No.
Series
Kit Description
Maximum Air Working Pressure Maximum Fluid Working
(Control Module) Pressure (Valves)
Low Pressure Non-Circulating Color Change Kits
24R915
24R916
24R917
24R918
A
A
A
A
2 color or 2 catalyst 100 psi (0.7 MPa, 7.0 bar)
4 color or 4 catalyst 100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
300 psi (2.068 MPa, 20.68 bar)
300 psi (2.068 MPa, 20.68 bar)
300 psi (2.068 MPa, 20.68 bar)
6 color
8 color
100 psi (0.7 MPa, 7.0 bar)
100 psi (0.7 MPa, 7.0 bar)
Low Pressure Circulating Color Change Kits
100 psi (0.7 MPa, 7.0 bar)
24R919
24R920
24R921
24R922
A
A
A
A
2 color
4 color
6 color
8 color
300 psi (2.068 MPa, 20.68 bar)
300 psi (2.068 MPa, 20.68 bar)
300 psi (2.068 MPa, 20.68 bar)
300 psi (2.068 MPa, 20.68 bar)
100 psi (0.7 MPa, 7.0 bar)
100 psi (0.7 MPa, 7.0 bar)
100 psi (0.7 MPa, 7.0 bar)
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Kit No.
Series
Kit Description
Maximum Air Working Pressure Maximum Fluid Working
(Control Module) Pressure (Valves)
High Pressure Non-Circulating Color Change Kits
24R959
24R960
24R961
24R962
A
A
A
A
2 color or 2 catalyst 100 psi (0.7 MPa, 7.0 bar)
4 color or 4 catalyst 100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
1500 psi (10.34 MPa, 103.4 bar)
1500 psi (10.34 MPa, 103.4 bar)
1500 psi (10.34 MPa, 103.4 bar)
6 color
8 color
100 psi (0.7 MPa, 7.0 bar)
100 psi (0.7 MPa, 7.0 bar)
High Pressure Acid Compatible Non-Circulating Catalyst Change Kits
24T579
24T580
A
A
2 catalyst (acid
compatible)
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
4 catalyst (acid
compatible)
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
High Pressure Circulating Color Change Kits
100 psi (0.7 MPa, 7.0 bar)
24R963
24R964
24R965
24R966
A
A
A
A
2 color
4 color
6 color
8 color
1500 psi (10.34 MPa, 103.4 bar)
1500 psi (10.34 MPa, 103.4 bar)
1500 psi (10.34 MPa, 103.4 bar)
1500 psi (10.34 MPa, 103.4 bar)
100 psi (0.7 MPa, 7.0 bar)
100 psi (0.7 MPa, 7.0 bar)
100 psi (0.7 MPa, 7.0 bar)
NOTE: Systems can use 1 to 30 colors and up to 4
catalysts. To add colors/catalysts:
• If current control module is full: If all solenoid ports
are in use in your control module(s), an additional
control module is needed. Order another complete
color change change kit, shown above.
• If current control module is not full: If empty
solenoid ports remain in your control module, see
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Intrinsically Safe Modules
These kits utilize intrinsically safe control modules that are installed in the hazardous area, near the dispense
valve. See the kit identification label for the product part number. See the module identification label for
maximum air working pressure, approval information and certification.
Intrinsically Safe Color Change Module Identification Label
Kit Identification Label
0359
II 2 G
Table 1 . Low Pressure, Non-Circulating Remote Mix Manifold Kits
Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)
Number of Color + Solvent Valves
Number of Catalyst + Solvent Valves
2
1
4
1
2
4
6
8
12
24V157
24V158
24V159
24V160
24V161
24V162
24V331
24V332
24V333
24V334
24V335
24V343
24V344
24V345
24V346
Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids,
manifolds, valves and a CAN cable).
13–18
13–24
13–30
24V163
24V164
24V165
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Table 2 . Low Pressure, Circulating Remote Mix Manifold Kits
Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)
Number of Color + Solvent Valves
Number of Catalyst + Solvent Valves
1
2
4
1
2
4
6
8
12
24V166
24V167
24V308
24V309
24V326
24V327
24V336
24V337
24V338
24V339
24V340
24V347
24V348
24V349
24V350
Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids,
manifolds, valves and a CAN cable).
13–18
13–24
13–30
24V328
24V329
24V330
Table 3 . High-Pressure, Non-Circulating Remote Mix Manifold Kits
Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)
Number of Color + Solvent Valves
Number of Catalyst + Solvent Valves
1
2
4
1
2
4
6
8
12
24V359
24V360
24V361
24V362
24V363
24V364
24V381
24V382
24V383
24V384
24V385
24V396
24V397
24V398
24V399
Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids,
manifolds, valves and a CAN cable).
13–18
13–24
13–30
24V365
24V366
24V367
Models continue on next page.
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Table 4 . High-Pressure, Circulating Remote Mix Manifold Kits
Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)
Number of Color + Solvent Valves
Number of Catalyst + Solvent Valves
1
2
4
1
2
4
6
8
12
24V369
24V370
24V371
24V372
24V373
24V374
24V389
24V390
24V391
24V392
24V393
24V402
24V403
24V404
24V405
Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids,
manifolds, valves and a CAN cable).
13–18
13–24
13–30
24V375
24V376
24V377
NOTE: Systems can use 1 to 30 colors and up to 4 catalysts. To add colors/catalysts:
• If current control module is full: If all solenoid ports are in use in your IS control module, an additional IS
control module is needed. Order a Control Module Expansion Kit, shown above.
• If current control module is not full: If empty solenoid ports remain in your control module, see
8
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Warnings
The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock, Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
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WARNING
INTRINSIC SAFETY
Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe
equipment will create a hazardous condition and can cause fire, explosion, or electric shock.
Follow local regulations and the following safety requirements.
• Be sure your installation complies with national, state, and local codes for the installation of
electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1
and 2 (Europe) Hazardous Location, including all of the local safety fire codes (for example,
NFPA 33, NEC 500 and 516, OSHA 1910.107, etc.).
• To help prevent fire and explosion:
• Do not install equipment approved only for a non-hazardous location in a hazardous
location. See model ID label for the intrinsic safety rating of your model.
• Do not substitute system components as this may impair intrinsic safety.
• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic
Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the
unit from the hazardous area when troubleshooting.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce
skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get
immediate surgical treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning
equipment.
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WARNING
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
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Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two
component materials.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
NOTICE
Isocyanate Conditions
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
Spraying or dispensing materials containing
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
Read and understand material manufacturer’s
warnings and material MSDS to know specific
hazards and precautions related to isocyanates.
• Use only moisture-proof hoses compatible with
ISO.
Prevent inhalation of isocyanate mists, vapors,
and atomized particulates by providing sufficient
ventilation in the work area. If sufficient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
To prevent contact with isocyanates, appropriate
personal protective equipment, including
chemically impermeable gloves, boots, aprons,
and goggles, is also required for everyone in the
work area.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
Changing Materials
NOTICE
Keep Components A and B Separate
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after
• Never interchange component A and component
B wetted parts.
hing.
flus
• Check with your material manufacturer for
mical compatibility.
• Never use solvent on one side if it has been
contaminated from the other side.
che
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the A (resin) side.
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming small, hard, abrasive
crystals, which become suspended in the fluid.
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Setup the Modules
Setup Non-IS Control Modules
NOTE: The PD2K System can use up to four pumps
and six color change modules in the non-hazardous
area. Use the following table to understand how
many color change modules are needed for the
number of pumps in your system, and which module
should be associated to which pump.
All Non-IS modules ship from the factory as Module
1 (Colors 1–8). Labels for Modules 2 through 6
are provided with the module kit. Affix the labels
according to your system configuration.
Table 5 . Relationship of Non-IS Color Change Control Modules to Pumps
System Pump Configuration Color Change Control Modules, Colors, and Catalysts
Color Catalyst
Total
Module 1 Module 2
Module
3 (Colors
17–24)
Module 4
(Colors
25–30)
Catalyst
1–2
Catalyst
3–4
Pump(s) Pump(s) Pumps
(Colors
1–8)
(Colors
9–16)
1
1
0
1
1
2
Not Applicable
Pump # 1 Pump # 1
Module # 5
Pump # 2
Module # 5
Pump # 2
2
2
1
0
3
2
Not Applicable
Pump # 1
Pump # 2
Pump # 3
Pump # 3
Pump # 1
Module
# 5
Module
# 6
2
2
4
Pump # 2 Pump # 4
Module # 5
Pump # 2
3
1
4
Pump # 4
3
4
0
0
3
4
Not Applicable
Not Applicable
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Configure each module according to its designated
number, as follows:
Non-IS Control Module Switch Settings
Control
Module
S6
S5
S4
NOTICE
ON
ON
ON
Module 1
Module 2
Module 3
Module 4
Module 5
Module 6
To avoid damaging the circuit boards, wear Part
No. 112190 grounding strap on your wrist and
ground appropriately.
OFF
ON
OFF
ON
OFF
ON
To avoid electrical component damage, remove all
system power before plugging any connectors.
OFF
ON
OFF
ON
OFF
ON
1. Remove electrical power from the system.
2. Open the color change module. Locate switches
S4, S5, and S6 on the control module board. The
switches are shipped in the OFF position.
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
3. For each module, set the switches to ON or OFF,
as shown in the following table.
OFF
OFF
OFF
4. Use the following figure and tables to determine
the solenoid valve assigned to each valve in the
valve manifold.
NOTE: There can be only one solvent valve and one
dump valve per pump.
Inlet Manifold
Outlet Manifold
Figure 1 Non-IS Control Module
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Non-IS Control Module 1
Inlet Manifold Outlet Manifold
Solenoid
Valve
Non-IS Control Module 4
Inlet Manifold Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
2
3
4
5
6
7
8
9
Solvent
Color 1
Color 2
Color 3
Color 4
Color 5
Color 6
Color 7
Color 8
1
2
3
4
5
6
7
8
9
Dump
1
2
3
4
5
6
7
8
9
(Solvent)*
Color 25
Color 26
Color 27
Color 28
Color 29
Color 30
Not Used
Not Used
1
2
3
4
5
6
7
8
9
(Dump)*
Color 25
Color 26
Color 27
Color 28
Color 29
Color 30
Not Used
Not Used
Color 1
Color 2
Color 3
Color 4
Color 5
Color 6
Color 7
Color 8
Non-IS Control Module 2
Inlet Manifold Outlet Manifold
Non-IS Control Module 5
Inlet Manifold Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
2
3
4
5
6
7
8
9
(Solvent)*
Color 9
1
2
3
4
5
6
7
8
9
(Dump)*
Color 9
1
2
3
4
5
6
7
8
9
(Solvent)*
Catalyst 1
Catalyst 2
Catalyst 3
Catalyst 4
Not Used
Not Used
Not Used
Not Used
1
2
3
4
5
6
7
8
9
(Dump)*
Catalyst 1
Catalyst 2
Catalyst 3
Catalyst 4
Not Used
Not Used
Not Used
Not Used
Color 10
Color 11
Color 12
Color 13
Color 14
Color 15
Color 16
Color 10
Color 11
Color 12
Color 13
Color 14
Color 15
Color 16
Non-IS Control Module 3
Inlet Manifold Outlet Manifold
Non-IS Control Module 6
Inlet Manifold Outlet Manifold
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
1
2
3
4
5
6
7
8
9
(Solvent)*
Color 17
Color 18
Color 19
Color 20
Color 21
Color 22
Color 23
Color 24
1
2
3
4
5
6
7
8
9
(Dump)*
Color 17
Color 18
Color 19
Color 20
Color 21
Color 22
Color 23
Color 24
1
2
3
4
5
6
7
8
9
(Solvent)*
Catalyst 3
Catalyst 4
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
1
2
3
4
5
6
7
8
9
(Dump)*
Catalyst 3
Catalyst 4
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
* There should be only one solvent valve and one dump valve per pump.
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Setup IS Control Modules
NOTE: Two IS color change control modules may
be installed in the hazardous area. The module
for colors 1–12 is labeled board 7. The module for
colors 13–30 is labeled board 8. An alternate label
for Module 8 (Colors 13–30) is provided with the
module kit. Affix the label according to your system
configuration.
3. For each module, set the switches to ON or OFF,
as shown in the following table.
IS Control Module Switch Settings
Control
Module
S6
S5
S4
ON
ON
ON
Module 7
Configure each module according to its designated
number, as follows:
OFF
ON
OFF
ON
OFF
ON
Module 8
NOTICE
OFF
OFF
OFF
To avoid damaging the circuit boards, wear Part
No. 112190 grounding strap on your wrist and
ground appropriately.
4. Use the following figure and tables to determine
the solenoid valve assigned to each valve in the
valve manifold.
To avoid electrical component damage, remove all
system power before plugging any connectors.
1. Remove electrical power from the system.
2. Open the color change module. Locate switches
S4, S5, and S6 on the control module board. The
switches may be shipped in the OFF position.
Figure 2 IS Control Module
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IS Control Module 7
IS Control Module 8
Valve
Solenoid
Color 13
Solenoid
1
Valve
Solenoid
1
Valve
Solenoid
Valve
Color
Solvent
Catalyst
Solvent
1
2
3
4
5
6
7
8
9
1
Color 22
Color 23
Color 24
Color 25
Color 26
Color 27
Color 28
Color 29
Color 30
Color 14
Color 15
Color 16
Color 17
Color 18
Color 19
Color 20
Color 21
2
3
4
5
6
7
8
9
2
3
4
5
6
7
8
9
Color 1
Color 2
Color 3
Color 4
Color 5
Color 6
Color 7
Color 8
2
3
4
5
6
7
8
9
Catalyst 1
Catalyst 2
Catalyst 3
Catalyst 4
Color 9
Color 10
Color 11
Color 12
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Installation
3. Using the equipment as a template, mark the
mounting holes on the wall at a convenient height
for the operator and so the equipment is easily
accessible for maintenance.
NOTE: The smaller color change control modules
must be mounted in the Non-IS area. The larger
remote color change module may be mounted
in the IS area.
• To avoid electric shock, turn off power at
the main circuit breaker before opening the
enclosure.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
4. Drill mounting holes in the wall. Install anchors
as needed.
5. Bolt the equipment securely.
• Do not substitute or modify system components
as this may impair intrinsic safety.
Air Supply
• Do not install equipment approved only for
non-hazardous location in a hazardous location.
See the identification label for the intrinsic safety
rating for your model.
Connect a clean and dry air supply to the air inlet
fitting (317) of each color change control module in
the non-hazardous area and each remote module in
the hazardous area. The fitting is for 1/4 in. (6 mm)
OD tubing. Use a 5 micron filter. Regulate the air
pressure to 85–100 psi (0.6–0.7 MPa, 6.0–7.0 bar).
Grounding
This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the
Pressure Relief Procedure in the PD2K Operation
Manual before installing the kit.
This equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
Mounting the Control Modules
Connect a ground wire from each color change
module in the non-hazardous area to a true earth
ground.
2. Ensure that the wall and mounting hardware
are strong enough to support the weight of the
equipment, fluid, hoses, and stress cause during
operation.
Intrinsically safe remote color change modules
located in the hazardous area must be connected to
a true earth ground in the hazardous area.
18
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Non-Hazardous Location
Connect the Color Change Control Modules
7. To install additional color control modules (six
maximum), mount the module(s) as described in
a 5–pin CAN cable from J11 of the previous color
control module to J7 of the next control module.
NOTE: Non-IS color change control modules provide
control for the pump’s inlet and outlet color/catalyst
change valves. Depending on the number of valves
in the system, as many as six control modules may
be installed in the non-hazardous location.
8. Replace the cover of the PD2K electrical control
box before turning on power to the system.
1. Mount the first non-IS color
control module as described in
2. Connect the 5–pin CAN cable (109) to J7 on the
color control module (108).
Figure 4 Cable Connection at PD2K Electrical
Control Box
Figure 3 Cable Connector J7 at Non-IS Color
Control Module
NOTICE
To avoid damaging the circuit boards, wear
Part No. 112190 grounding strap on your wrist
and ground appropriately.
To avoid electrical component damage,
remove all system power before plugging any
connectors.
3. Remove electrical power from the system.
4. Remove the cover from the PD2K electrical
control box.
5. Install the supplied 2–cable grommet (110) on
the cable (109) and secure the grommet to the
side of the electrical control box.
6. Connect the cable (109) to J2 on the non-IS side
of the isolation board inside the electrical control
of M12 CAN cables for use in a non-hazardous
area.
Figure 5 Detail of Isolation Board Cable Connections
333282B
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Install the Valve Manifolds
NOTE: Always label the color connections to prevent
cross-connections. Label the inlet manifold, outlet
manifold, and each color valve with its assigned color.
The solvent and dump valves should be furthest from
the manifold stack primary inlet or outlet.
with 16 valve positions (14 colors). On high
pressure systems, the supplied bracket (101) will
accommodate a manifold with 14 valve positions
(12 colors). A larger valve stack will require a
customer supplied/sourced bracket.
3. Repeat for the opposite side of the PD2K.
1. Install a mounting bracket (101) on the PD2K
with four screws (103). High pressure systems:
For stability, be sure to fasten the bottom screws
(103) to the pump bracket.
4. Connect the air lines from the solenoids to the
NOTE: On high pressure systems, see
5. Connect the fluid supply lines to the valves. See
2. Install the inlet and outlet valve manifolds (102)
on the mounting bracket (101) with four screws
(104), washers (105), and nuts (106).
NOTE: On low pressure systems, the supplied
bracket (101) will accommodate a manifold
Figure 6 Install the Valve Manifolds
20
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Install the Back Pressure Regulator (High Pressure Systems Only)
NOTE: The back pressure regulator is required on
high pressure systems to prevent the system’s feed
pumps from overdriving the dosing pumps during
color change pump flush and color fill operations.
Adjust the back pressure during the dump process to
be approximately 75% of the supply pressure from
the feed pumps, but never more than 300 psi (2.1
MPa, 21 bar) less than the supply pressure.
5. Connect the fluid supply lines to the valves. See
Install the back pressure regulator (120) and
attaching hardware at the dump valve of the outlet
manifold stack.
1. Install the gauge (123) in the open port of the
tee (122).
2. Screw the tee (122) onto the dump valve fitting of
the outlet manifold stack.
3. Assemble the two nipples (121) to the back
pressure regulator (120). Screw the regulator
assembly into the tee (122) as shown.
Figure 7 Install Back Pressure Regulator at Dump
Valve of Outlet Stack
4. Connect a 1/4 npt(f) dump line to the downward
facing nipple (121).
333282B
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Hazardous Location
Connect Remote Color Change Control
Module
NOTE: IS color change control modules
provide control for remote color/catalyst change
valves located in the hazardous location
for use with automatic spray systems. A
maximum of two IS control modules may
be installed in the hazardous location. See
IS Color Change Control Modules, page 66 for a list
of modules approved for installation in a hazardous
location.
NOTICE
To avoid damaging the circuit boards, wear Part
No. 112190 grounding strap on your wrist and
ground appropriately.
Figure 8 Intrinsically Safe Cable Connections
3. Connect the hazardous location cable (C1) to J7
on the remote color control module (108).
To avoid electrical component damage, remove all
system power before plugging any connectors.
Only approved cables may be used in the
hazardous location. Hazardous location cables are
marked with a light blue flag next to each connector.
list of M12 CAN cables for use in a hazardous area.
1. Remove electrical power from the system.
2. Mount the first remote color change
control module as described in
Figure 9 Cable Connectors J7 and J11 at IS
Color Control Module
4. Remove the cover from the PD2K electrical
control box. Install the grommet (G) on the
supplied cable (C1) and secure the grommet
to the side of the electrical control box. Locate
J4 on the IS side of the isolation board in the
electrical control box. Connect the cable (C1) to
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J11 on the first color control module to J7 on the
second module.
6. Replace the cover of the PD2K electrical control
box before turning on power to the system.
Install the Remote Valve Manifolds
1. Using the equipment as a template, mark the
mounting holes on the wall at a convenient height
for the operator and so the equipment is easily
accessible for maintenance. Mount the remote
valve manifolds near the remote color module
and the automatic dispensing device.
2. Install the mounting brackets for the color valve
manifolds and the catalyst valve manifolds. See
equipment securely.
3. Install the color and catalyst valve manifolds to
the brackets with four screws, washers, and nuts.
Figure 10 Detail of Isolation Board Cable
Connections
4. Connect the air lines from the solenoids to the
5. If your system includes a second remote
color control module mount it as described in
the supplied hazardous location cable (C2) from
5. Connect the fluid supply lines to the valves. See
333282B
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Install the Remote Mix Manifold
Connect the Valve Air Lines
1. Using the equipment as a template, mark the
mounting holes on the wall or robot arm, near the
automatic dispensing device.
Non-Hazardous Area
1. Connect 5/32 in. (4 mm) OD air tubes from the
inlet solenoids to the air inlets of each inlet valve,
using the label inside of the color control module
2. Install the remote mix manifold. See
the equipment securely.
2. Repeat for the outlet valves.
Hazardous Area
3. Install the remote mix manifold to the bracket
with four screws.
Connect 5/32 in (4 mm) OD air tubes from the
solenoids to the air inlet of each valve, using the
labels inside of the remote color control module as a
4. Connect the fluid supply lines to the remote mix
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2. Use the top valve of the outlet valve stack as the
dump valve (D). Connect a waste dump line to
the 1/4 npt(m) dump valve outlet on the color and
catalyst valve stacks.
Connect the Fluid Lines
Connect Non-Circulating Fluid Lines
NOTE: There can be only one solvent valve (S) and
one dump valve (D) per pump.
3. Connect the supply line for each color to the
corresponding color valve fitting (C1, C2, etc.) on
the inlet color valve stack.
NOTE: On high pressure systems, see
4. Connect a supply line from the bottom fitting of
the inlet color valve stack to the inlet manifold of
the material A dosing pump.
1. Use the top valve of the inlet valve stack as the
solvent valve (S). Connect a solvent supply line
to the 1/4 npt(m) solvent valve inlet on the color
and catalyst valve stacks.
5. Connect a supply line from the outlet manifold of
the material A dosing pump to the bottom fitting
of the outlet color valve stack.
Remote
Color and
Catalyst
Valve
Hazardous
Area
Manifolds
Non-
Hazardous
Area
Non-IS
inlet and
outlet
color and
catalyst
valve
manifolds
Valve Manifold Stack Schematic
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6. Connect a dedicated supply line for each color
to the corresponding color valve fitting (C1, C2,
etc.) on the outlet color valve stack. Connect the
other end of each line to the corresponding color
valve fitting on the remote color stack.
13. Connect the static mixer to the outlet valve of the
remote mix manifold.
14. Connect a fluid line from the static mixer to the
automatic dispense device.
7. Connect a supply line from the outlet valve on
the bottom of the remote color valve stack to inlet
A on the remote mix manifold.
8. Connect the supply line for each catalyst to the
corresponding catalyst valve fitting on the inlet
catalyst valve stack.
9. Connect a supply line from the bottom fitting of
the inlet catalyst valve stack to the inlet manifold
of the material B dosing pump.
10. Connect a supply line from the outlet manifold of
the material B dosing pump to the bottom fitting
of the outlet catalyst valve stack.
Figure 11 Color Change Connections
(Non-Circulating System)
11. Connect a dedicated supply line for each catalyst
to the corresponding catalyst valve fitting on the
outlet catalyst valve stack. Connect the other
end of each line to the corresponding catalyst
valve fitting on the remote catalyst valve stack.
KEY
A
Air inlet
W
Seal weep and
lubrication port
NOTE: If your system uses more colors than
catalysts, branch the catalyst line to connect it to
each mix manifold. Install a check valve on each
branch of the catalyst line.
S
Solvent fitting
Color 1 fitting
Color 2 fitting
C1
C2
NOTE: For ease of maintenance, install a ball
valve at all fluid line tees.
12. Connect a supply line from the outlet valve of
the remote catalyst valve stack to inlet B on the
remote mix manifold.
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Connect Circulating Fluid Lines
Circulation valves enable constant circulation of a
color when that color is not being sprayed:
b. Connect a dedicated fluid supply line for
each color to the corresponding color valve
(C1, C2, etc.) on the outlet color valve stack.
Connect the other end of each line to the
corresponding color valve on the remote
color stack.
• When a color valve is closed, the system bypasses
the dosing pump by directing that color from the
inlet color valve to the outlet color valve to the
remote color valve, through a circulation line, then
back to the color supply.
c. Connect a 1/4 npt(f) circulation line from the
circulation port on each remote valve back to
the fluid supply container.
• When a color valve is open, the circulation line is
shut off. The color is directed through the material
A dosing pump and out to the remote color valve
stack and mix manifold, as in normal operation.
NOTE: On circulating systems, install a cap (T) on
any unused valve fittings.
NOTE: There can be only one solvent valve (S) and
one dump valve (D) per pump.
NOTE: On high pressure systems, see
1. Connect all fluid lines as described in
These lines are used during normal mixing and
spraying.
Figure 12 Valve Manifold Connections (Circulating
System)
2. Connect the circulation lines as follows:
KEY
a. Connect a 1/4 npt(f) circulation line for each
color from the color valve’s circulation fitting
(R1, R2, etc.) on the inlet color valve stack
(B) to the corresponding circulation fitting
(R1, R2, etc.) on the outlet color valve
stack (C). This circulation line bypasses the
material A dosing pump when the color valve
is closed, allowing continuous circulation of
that color.
D
S
Dump valve fitting
Solvent fitting
C1 Color 1 fitting
C2 Color 2 fitting
R1 Color 1 circulation fitting
R2 Color 2 circulation fitting
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Fluid Flow Schematic Diagram in Circulating Mode (Pump Not Shown for Clarity)
KEY
A
Color supply
B
Inlet color stack
C
Outlet color stack
D
Remote color stack
Remote mix manifold
Automatic spray gun
Return line to fluid supply
E
F
G
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Install an Expansion Kit
6. Install the valves as follows:
a. For a one valve kit, remove the plug
(4) and o-ring (2). Install a new o-ring
(2), the valve (3), and retainer (5),
using the valve installation tool. See
b. For a manifold kit with one valve, install
the o-ring (2), valve (3), and retainer (5),
using the valve installation tool. See
Replace a Color Valve, page 43. Install the
plug (4) in the unused manifold port.
Expansion Kits are available to add valves or
manifolds to your system. For each additional
color/catalyst desired, order a Non-IS Expansion
Kit and a corresponding IS Expansion Kit. See
Expansion Kits, page 69 for available kits.
c. For a manifold kit with two valves, install
the o-rings (2), valves (3), and retainers
(5), using the valve installation tool. See
NOTE: Remember that you may need up to 6 Non-IS
control modules and up to 2 IS control modules.
7. Install the o-ring(s) (12) and fluid fitting(s) (13).
Follow Steps 1–7 to install solenoids, manifolds, and
valves, first in the Non-IS area, and then in the IS
area.
8. For each color/catalyst, connect fluid lines from
the source to the input color/catalyst stack. Then,
connect fluid lines from each output valve to the
corresponding remote color change valve.Install
the air fitting(s) (14).
1. Remove electrical power from the system.
2. Relieve pressure as described in your PD2K
Operation Manual.
9. Connect the tubing from the solenoid valve(s)
(see step 3) to the fitting(s) in both the IS and
and Non-IS areas.
3. Open the control module cover. Install the
solenoid(s) and air fitting(s) at the appropriate
position(s) in the solenoid manifold. See
Setup the Modules, page 13. Connect one end
of the tubing to the solenoid’s air fitting.
10. Install the control module covers.
11. Return the unit to service.
4. Connect the solenoid wires to the appropriate
pins on the control module board. See
NOTE: If installing a one valve kit, it is not
necessary to disassemble the manifold stack as
shown in the figure. Skip step 5 and go on to
step 6.
5. If your kit is adding a manifold block (1), remove
the screws (10). Slide the existing manifolds off
the rods (15, 16), keeping the manifolds in the
correct order. Install the new manifold block (1).
The new block must be in the bottom position to
maintain correct location of the solvent and dump
valves. Screw the rods (16) included in the kit
into the existing rods. Slide the existing manifold
blocks onto the rods, being sure that they are in
the same positions as before. Ensure all o-rings
(6, 17) are in place, then install the screws (10).
30
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Figure 13 Install an Expansion Kit (Low Pressure
Valve Manifold Shown)
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Troubleshooting
NOTE: Check all possible remedies before disassembling the system.
Color Change Solenoid Valves
NOTE: Refer to Electrical Schematics, page 36. 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 Check that air pressure is at least 85 psi (0.6 MPa, 6.0 bar). Do not go above 100
set too high or too low.
psi (0.7 MPa, 7.0 bar).
2. Air or electrical lines
Visually inspect air and electrical lines for kinks, damage, or loose connections.
damaged or connections Service or replace as needed.
are loose.
3. Solenoid failure.
proceed with the following checks. If not lit, go to Cause 4.
Remove the connector for the applicable solenoid and measure voltage across
the pins on the board:
• In a non-hazardous location, replace the solenoid if voltage is 24 Vdc.
• In a hazardous location, replace the solenoid if voltage is between 9–15 Vdc.
Test the valves as explained under Maintenance Screen 4 in your PD2K
Operation manual. Valves should open and close quickly. If the valves actuate
slowly, it could be caused by:
• Air pressure to the valve actuators is too low. See Cause 1.
• Solenoid is clogged. Make sure the air supply has a 5 micron filter installed.
• Something is restricting the solenoid or tubing. Check for air output from the
air line for the corresponding solenoid when the valve is actuated. Clear the
restriction.
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Cause
Solution
4. Control board or cable If there is no voltage across the pins on the board or it is less than 9 Vdc, check
failure.
LEDs D8, D9, and D10. If they are lit and functioning properly, or other solenoids
in the module are working properly, replace the color change board.
If D9 is not lit:
• Verify the condition of the fuse (F1) and replace if necessary. See
• Check if the cable is disconnected or damaged.
• Check the isolation board. See the PD2K Repair-Parts manual.
If D8 is not blinking:
• Cycle the system power.
• Check if the cable is disconnected or damaged.
• Check the isolation board. See the PD2K Repair-Parts manual.
If D10 is not occasionally blinking:
• Check if the cable is disconnected or damaged.
• Check the isolation board. See the PD2K Repair-Parts manual.
333282B
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Color Change Board
NOTICE
To avoid damaging the circuit boards, wear Part
No. 112190 grounding strap on your wrist and
ground appropriately.
To avoid electrical component damage, remove all
system power before plugging any connectors.
Figure 14 Color Change Board
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Color Change Board Diagnostics
ID
Component or Indicator
Function
D8
D9
LED (green)
LED (green)
Blinks (heartbeat) during normal operation.
Turns on when power is supplied to the
board.
D10
LED (yellow)
Turns on when board is communicating with
electronic control.
D27–D39,
D41, D43–D46
LED (green)
Turn on when a signal is sent to actuate the
related solenoid valve.
F1
Fuse, 0.125 A, 125 V
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Electrical Schematics
NOTE: The electrical schematic illustrates all possible
wiring expansions in a ProMix PD2K system. Some
components shown are not included with all systems.
for a list of cable options.
2
2
CABLE
(15V206)
CABLE
(15V206)
065161, 065159
INTEGRATION
RELAY
POWER MODULE
2 POSITION
SWITCH
(24R257)
(16U725)
GATEWAY
5
CABLE
16T658
24V
POWER
SUPPLY
(16T660)
48V-10A POWER SUPPLY
(16U820)
LINE FILTER
(16V446)
AWI
GATEWAY
(24R910)
CABLE
16H078
CABLE
(15V206)
CABLE
(15V206)
CABLE
(15V206)
2
2
2
5
TERMINAL BLOCK
(114095)
GUN TRIGGER INPUTS
TERMINAL BLOCKS WITH FUSES
119159
119159
119159
119159
POWER IN
16T072
CAN
IS BOARD
(24M485)
SOLENOID (121324)
PRESSURE SW (121323)
GFB
INTERFACES
GCA
MODULE
EFCM
FAN
(24P658)
FAN
(24P658)
SOLVENT CUTOFF (121324)
ENCODER AND MOTOR
(16P036, 16P037)
WIRE HARNESS
ENCODER AND MOTOR
(16P036, 16P037)
WIRE HARNESS
SWITCH (120278)
SWITCH (120278)
SOLVENT
FLOW
INPUTS
(24P684, 24P685)
(24P684, 24P685)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
(24N913)
BARRIER
BOARD
(248192)
SPLITTER
(16P243)
SOLVENT METER (258718)
PUMP OUTLET
TRANSDUCER
PUMP OUTLET
TRANSDUCER
SAFETY INTERLOCK SWITCH
(16P289, 16P290)
(16P289, 16P290)
3
LIGHT
TOWER
(15X472)
ADVANCED
DISPLAY MODULE
(24E451)
PUMP V/P FOR
FLUID REG.
PUMP V/P FOR
FLUID REG.
CABLE
(121003)
UP
UP
DOWN
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
COLOR CHANGE MODULE 7
(24R219)
7
4
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
COLOR CHANGE MODULE 8
(24R219)
7
FAN
(24P658)
FAN
(24P658)
1
CABLE (16V429)
BOOTH CONTROL (24M731)
ENCODER AND MOTOR
(16P036, 16P037)
WIRE HARNESS
ENCODER AND MOTOR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
(24P684, 24P685)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
HAZARDOUS LOCATION
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
NON-HAZARDOUS LOCATION
PUMP V/P FOR
FLUID REG.
PUMP V/P FOR
FLUID REG.
UP
UP
DOWN
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
Figure 15 Electrical Schematic, Sheet 1
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CONTINUED ON PAGE 3
CONTINUED ON PAGE 3
UNUSED
UNUSED
5
4
3
2
1
10
8
UNUSED
CABLE (121227)
CABLE
CABLE
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
3
P3
P4
P3
P4
AWI
(121227)
(121001)
16T072
1 2 3 4 5
GATEWAY
(24R910)
INTEGRATION
GATEWAY
3
3
GCA MODULE
EFCM
1 2 3 4 5
CAN IS BOARD
(NON IS)
2
5
1
5
(IS)
4
3
(24M485)
1 2 3 4 5
1 2 3 4 5
(24N913)
+12VDC
COM
GFB INTERFACE
(121324)
1
2
3
4
5
6
7
8
9
UNUSED
UNUSED
+12VDC
COM
1 2 3
5
1
2
3
+12VDC
COM
SPLITTER
(16P243)
SOLVENT CUTOFF (121324)
PWR (RED)
UNUSED
10
11
12
2
SIG (WHITE)
COM (BLACK)
SHIELD/GRN
5 4
3
1
BARRIER
BOARD
1
2
UNUSED
SOLVENT
METER
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
(248192)
(258718)
RED WIRE (065161)
GROUND BAR
4
BLACK WIRE (065159)
25 PIN D-SUB CABLE
(16T659)
24V
POWER
SUPPLY
(16T660)
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
1
BREAKOUT MODULE PUMP 1 (24N527)
BREAKOUT MODULE PUMP 2 (24N527)
GRND (GRN/YEL)
7
7
2
3
1 2 3 4
4
5
6
1 2 3 4
8
1 2 3 4
2
3
1 2 3 4
4
5
6
1 2 3 4
8
1 2 3 4
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4
5 6 7 8
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4
5 6 7 8
13 A1(+) A2(-)
RELAY
14
N
L
GRND
48V-10A
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 1
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 2
POWER SUPPLY
(16U820)
+
-
SEE DETAIL A OR B
SEE DETAIL A OR B
N03 N03
2 POSITION
SWITCH
(16U725)
N04 N04
MANIFOLD
MANIFOLD
+ - + - + - + -
G3000
METER
PUMP 1
G3000
METER
PUMP 2
CABLE
(16T658)
(EITHER, 239716,
258718,16M510,
OR 16M519)
(EITHER, 239716,
258718,16M510,
OR 16M519)
L
L
N
+ - + - + - + -
GRND
SCREW
LINE
FILTER
(16V446)
GRND
SCREW
TWISTED PAIR CABLE (16W159)
TWISTED PAIR CABLE (16W159)
GRND
N
CABLE
(16H078)
DETAIL B, HIGH PRESSURE
PUMPS (24M707, 24M715)
DETAIL A, LOW PRESSURE
PUMPS (24M706, 24M714)
L
L
N GRND
BREAKOUT MODULE
(24N527)
BREAKOUT MODULE
(24N527)
TERMINAL
BLOCK
(114095)
2
3
2
3
1 2 3 4 5
1 2 3 4
1 2 3 4 5
1 2 3 4
WIRE HARNESS
(24P684)
WIRE HARNESS
(24P685)
N GRND
DRAIN/FOIL
DRAIN/FOIL
1 2 3 4 5 6 7 8 9
1011
12
1 2 3 4 5 6 7 8 9
10
1 2
1 2 3 4 5 6 7 8 9
1011 12 1 2 3 4 5 6 7 8 9
10
MOTOR
MOUNTING
SCREW
PUMP ENCODER AND MOTOR
(16P036)
PUMP ENCODER AND MOTOR
(16P037)
MOTOR
MOUNTING
SCREW
Figure 16 Electrical Schematic, Sheet 2, Part 1
CONTINUED ON THE NEXT PAGE
333282B
37
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GUN TRIGGER INPUTS
SIG
1
COM
SIG
2
3
4
COM
SIG
5
COM
SIG
6
6
7
8
COM
SIG
9
10
11
12
GFB PRESSURE SWITCH (121323)
SOLVENT FLOW SWITCH 1 (120278)
COM
SIG
COM
GCA MODULE
EFCM
FLOW RATE ANALOG IN 1
1
FLOW RATE ANALOG COMMON 1
FLOW RATE ANALOG IN 2
FLOW RATE ANALOG COMMON 2
FLOW RATE ANALOG IN 3
FLOW RATE ANALOG COMMON 3
FLOW RATE ANALOG IN 4
FLOW RATE ANALOG COMMON 4
SIG
2
3
4
5
6
7
9
7
8
(24N913)
9
10
11
12
SOLVENT FLOW SWITCH 2 (120278)
COM
SIG
COM
SAFETY INTERLOCK SWITCH
CABLE
1
2
3
4
5
1
1
ADVANCED
2
LIGHT
TOWER
(15X472)
2
3
DISPLAY MODULE
3
4
5
4
(24E451)
3
4
5
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
(121003)
3
4
25 PIN D-SUB CABLE
(16T659)
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
1
BREAKOUT MODULE PUMP 3 (24N527)
BREAKOUT MODULE PUMP 4 (24N527)
7
7
2
3
1 2 3 4
4
5
6
1 2 3 4
8
1 2 3 4
2
3
1 2 3 4
4
5
6
1 2 3 4
8
1 2 3 4
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4
5 6 7 8
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4
5 6 7 8
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 3
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 4
SEE DETAIL A OR B
SEE DETAIL A OR B
MANIFOLD
MANIFOLD
G3000
METER
PUMP 3
G3000
METER
PUMP 4
(EITHER, 239716,
258718,16M510,
OR 16M519)
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
GRND
SCREW
TWISTED PAIR CABLE (16W159)
TWISTED PAIR CABLE (16W159)
Figure 17 Electrical Schematic, Sheet 2, Part 2
CONTINUED ON THE NEXT PAGE
38
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FROM CAN IS BOARD (24M485) ON PAGE 2
FROM CAN IS BOARD (24M485) ON PAGE 2
CABLE (15V206)
2
1 2 3 4
COLOR
5
CHANGE
MODULE 1
(COLORS
1 THRU 8)
MANIFOLD
MANIFOLD
1
2
3
4
5
6
6
5
4
3
2
1
COM
+12VDC
COM
FLUSH
COLOR 1
COLOR 2
DUMP
+12VDC
COM
+12VDC
COM
COLOR 1
COLOR 2
J8
J9
+12VDC
COM
+12VDC
+12VDC
COM
6
6
5
4
3
2
1
1
COM
+12VDC
COM
COLOR 3
COLOR 4
COLOR 5
COLOR 3
COLOR 4
COLOR 5
324 J15
+12VDC
COM
+12VDC
COM
J16
+12VDC
COM
5
6
+12VDC
COM
+12VDC
1
2
6
5
4
3
2
1
+12VDC
COM
COM
COLOR 6
COLOR 7
COLOR 8
+12VDC
COM
COLOR 6
COLOR 7
COLOR 8
34 J14
+12VDC
COM
J10
+12VDC
COM
+12VDC
5
6
+12VDC
COM
1 2 3 4
5
1 2 3 4
5
COLOR
CHANGE
MODULE 2
(COLORS
9 THRU 16)
CATALYST
CHANGE
MODULE 5
(CATALYST
1 THRU 4)
MANIFOLD
MANIFOLD
MANIFOLD
MANIFOLD
1
2
1
2
3
6
5
4
3
2
1
6
5
COM
COM
+12VDC
COM
+12VDC
COM
DUMP
*FLUSH
COLOR 9
COLOR 10
DUMP*
FLUSH
CATALYST 1
CATALYST 2
+12VDC
COM
+12VDC
COM
34 J8
J9
4 J8
J9 43
+12VDC
COM
+12VDC
COM
CATALYST 1
CATALYST 2
COLOR 9
COLOR 10
+12VDC
COM
+12VDC
+12VDC
COM
+12VDC
5
6
5
6
2
1
+12VDC
COM
+12VDC
COM
6
6
6
5
4
3
2
1
6
5
4
3
2
1
1
1
2
3
4
5
6
COM
COM
+12VDC
COM
+12VDC
COM
CATALYST 3
CATALYST 4
COLOR 11
COLOR 12
COLOR 13
COLOR 11
COLOR 12
COLOR 13
324 J15
CATALYST 3
CATALYST 4
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
J16
J15
J16
+12VDC
COM
+12VDC
UNUSED
UNUSED
5
6
+12VDC
COM
UNUSED
UNUSED
+12VDC
1
2
1
2
3
4
5
6
6
5
4
3
2
1
6
5
4
3
2
1
+12VDC
COM
COM
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
COLOR 14
COLOR 15
COLOR 16
+12VDC
COM
COLOR 14
COLOR 15
COLOR 16
34 J14
+12VDC
COM
J14
J10
J10
+12VDC
COM
+12VDC
5
6
+12VDC
COM
1 2 3 4
5
1
2
3 4
5
1 2 3 4
5
1 2 3 4
5
COLOR
CHANGE
MODULE 3
(COLORS
17 THRU 24)
COLOR
CHANGE
MODULE 4
(COLORS
25 THRU 32)
MANIFOLD
MANIFOLD
MANIFOLD
MANIFOLD
1
2
3
1
2
3
4
5
6
6
5
4
3
2
1
6
5
4
3
2
1
COM
COM
+12VDC
COM
+12VDC
COM
*FLUSH
COLOR 17
COLOR 18
DUMP*
*FLUSH
COLOR 25
COLOR 26
DUMP*
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
COLOR 17
COLOR 18
COLOR 25
COLOR 26
J8
J9
4 J8
J9
+12VDC
COM
+12VDC
+12VDC
COM
+12VDC
5
6
+12VDC
COM
+12VDC
COM
6
6
6
5
4
3
2
1
6
5
4
3
2
1
1
2
3
4
5
6
1
COM
COM
+12VDC
COM
+12VDC
COM
COLOR 19
COLOR 20
COLOR 21
COLOR 19
COLOR 20
COLOR 21
COLOR 27
COLOR 28
COLOR 29
COLOR 27
COLOR 28
COLOR 29
324 J15
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
J16
J15
J16
+12VDC
COM
+12VDC
COM
+12VDC
5
6
+12VDC
COM
+12VDC
COM
+12VDC
1
2
3
4
5
6
1
2
6
5
4
3
2
1
6
5
4
3
2
1
+12VDC
COM
COM
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
COM
COLOR 22
COLOR 23
COLOR 24
+12VDC
COM
COLOR 22
COLOR 23
COLOR 24
COLOR 30
+12VDC
UNUSED
UNUSED
UNUSED
UNUSED
COLOR 30
34 J14
+12VDC
COM
J14
J10
J10
+12VDC
COM
+12VDC
5
6
+12VDC
COM
5 4
3
2
1
1 2 3 4
5
CABLE (15V206)
2
Figure 18 Electrical Schematic, Sheet 3
* May be unused in some configurations.
CONTINUED ON THE NEXT PAGE
333282B
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CATALYST
CHANGE
MODULE 6
(CATALYST
3 THRU 4)
MANIFOLD
MANIFOLD
1
2
3
4
5
6
6
5
4
3
2
1
COM
+12VDC
COM
DUMP
FLUSH
+12VDC
COM
+12VDC
COM
CATALYST 3
CATALYST 4
CATALYST 3
CATALYST 4
J8
J9
+12VDC
COM
+12VDC
+12VDC
COM
6
6
5
4
3
2
1
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
324 J15
J16
5
6
1
2
3
4
5
6
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J14
J10
1 2 3 4 5
5 4 3 2
1
CATALYST
CHANGE
MODULE 5
(CATALYST
1 THRU 2)
MANIFOLD
MANIFOLD
1
6
5
COM
+12VDC
COM
DUMP
2
FLUSH
CATALYST 1
CATALYST 2
+12VDC
COM
3
J9 43
+12VDC
COM
CATALYST 1
CATALYST 2
4 J8
+12VDC
COM
+12VDC
5
6
2
1
+12VDC
COM
6
6
5
4
3
2
1
1
2
3
4
5
6
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J15
J16
1
2
3
4
5
6
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J14
J10
1 2 3 4 5
1 2 3 4 5
COLOR
CHANGE
MODULE 4
(COLORS
25 THRU 32)
Figure 19 Electrical Schematic, Sheet 3, Alternate
Configuration for Catalyst Change Control
CONTINUED ON THE NEXT PAGE
40
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FROM CAN IS BOARD (24M485) ON PAGE 2
NON-HAZARDOUS LOCATION
HAZARDOUS LOCATION
1 2 3 4
5
COLOR
CHANGE
MODULE 7
(COLORS
33 THRU 40)
MANIFOLD
MANIFOLD
1
2
3
4
5
6
6
5
4
3
2
1
COM
+12VDC
COM
COLOR FLUSH
COLOR 1
CATALYST FLUSH
+12VDC
COM
+12VDC
COM
CATALYST 1
CATALYST 2
+12VDC
COM
+12VDC
J8
J9
+12VDC
COM
COLOR 2
7
6
5
4
3
2
1
1
2
3
4
5
6
COM
+12VDC
COM
COLOR 3
COLOR 4
COLOR 5
CATALYST 3
CATALYST 4
COLOR 9
+12VDC
COM
+12VDC
COM
J15
J16
+12VDC
COM
+12VDC
+12VDC
COM
1
2
3
4
5
6
6
5
4
3
2
1
+12VDC
COM
COM
COLOR 6
COLOR 7
COLOR 8
COLOR 10
COLOR 11
COLOR 12
+12VDC
COM
+12VDC
COM
J14
+12VDC
COM
+12VDC
J10
+12VDC
COM
1 2 3 4
5
1 2 3 4
5
COLOR
CHANGE
MODULE 8
(COLORS
41 THRU 48)
MANIFOLD
MANIFOLD
1
2
3
4
5
6
6
5
4
3
2
1
COM
+12VDC
COM
COLOR 13
COLOR 14
COLOR 15
COLOR 22
COLOR 23
COLOR 24
+12VDC
COM
+12VDC
COM
J8
J9
+12VDC
COM
+12VDC
+12VDC
COM
7
6
5
4
3
2
1
1
COM
+12VDC
COM
COLOR 16
COLOR 17
COLOR 18
COLOR 25
COLOR 26
COLOR 27
324 J15
+12VDC
COM
+12VDC
COM
J16
+12VDC
COM
5
6
+12VDC
COM
+12VDC
1
2
3
4
5
6
6
5
4
+12VDC
COM
COM
COLOR 19
COLOR 20
COLOR 21
COLOR 28
COLOR 29
COLOR 30
+12VDC
COM
+12VDC
COM
J14
J10 3
+12VDC
COM
+12VDC
2
1
+12VDC
COM
5 4 3 2
1
5 4 3 2 1
BOOTH CONTROL
(24M731)
Figure 20 Electrical Schematic, Sheet 3, Hazardous
Location
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Optional Cables and Modules
NOTE: The total length of all cable used in the system must not exceed 150 ft (45 m). See the
M12 CAN Cables, for Hazardous Locations
25 Pin D-SUB Cables, for Non-Hazardous
Locations Only
NOTE: The total length of cable used in the
hazardous location must not exceed 120 ft (36 m).
16T659
2.5 (0.8)
16V659
6.0 (1.8)
Cable Part No.
Length ft (m)
16V423
16V424
16V425
16V426
16V427
16V428
16V429
16V430
2.0 (0.6)
3.0 (1.0)
6.0 (2.0)
10.0 (3.0)
15.0 (5.0)
25.0 (8.0)
50.0 (16.0)
100.0 (32.0)
Alternates for Communication Module 24R910,
for Non-Hazardous Locations Only
Module Part No.
Module Part No.
CGMDN0*, DeviceNet
CGMEP0*, Ethernet IP
CGMPB0*, Profibus
CGMPN0*, Profinet
* You must purchase Map Token Kit 17C087 for
use with these kits.
Alternates for Color Change Modules
by Part Number (Factory Configuration), for
Non-Hazardous Locations Only, see page 61
M12 CAN Cables, for Non-Hazardous
Locations Only
15U531
15U532
15V205
15V206
15V207
15V208
15U533
15V213
2.0 (0.6)
3.0 (1.0)
6.0 (2.0)
10.0 (3.0)
15.0 (5.0)
25.0 (8.0)
50.0 (16.0)
100.0 (32.0)
Module Part No.
Description
24T557
24T558
24T559
24T560
2 color/2 catalyst
4 color/4 catalyst
6 color/6 catalyst
8 color/8 catalyst
Alternates for Color Change Modules by Part
Number (Factory Configuration), for Hazardous
Locations Only, see page 62
24T571
2 color/2 catalyst
4 color/2 catalyst
6 color/2 catalyst
8 color/2 catalyst, 13–24
color
CAN Cables, for Non-Hazardous
Locations Only
24T572
24T573
24T574
Cable Part No.
125306
123422
121000
121227
121001
121002
121003
120952
121201
121004
121228
Length ft (m)
1.0 (0.3)
1.3 (0.4)
1.6 (0.5)
2.0 (0.6)
3.0 (1.0)
5.0 (1.5)
10.0 (3.0)
13.0 (4.0)
20.0 (6.0)
25.0 (8.0)
50.0 (15.0)
24T774
24T775
24T776
24T777
24T778
12 color/2 catalyst
4 color/4 catalyst
6 color/4 catalyst
8 color/4 catalyst
12 color/4 catalyst, 13–30
color
24T779
13–18 color
42
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Repair
• To avoid electric shock, turn off power at the
main circuit breaker before opening the control
module.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
Figure 21 Remove Retainer
• Do not substitute or modify system components
as this may impair intrinsic safety.
3. Using the other end of the tool (114), screw it all
the way onto the valve (3). Pull the valve from
the manifold.
NOTICE
To avoid damaging the circuit boards, wear Part
No. 112190 grounding strap on your wrist and
ground appropriately.
To avoid electrical component damage, remove all
system power before plugging any connectors.
Replace a Color Valve
Use the following procedure to replace a valve,
whether the valve is part of the color stacks near the
pump or part of the remote color stacks.
Figure 22 Remove the Valve
NOTE: See manual 332454 to repair the valve.
4. Install the valve in the reverse order of
disassembly. Be sure all o-rings are in place
and lubricated, and that the valve is seated
completely in the manifold.
1. Flush and relieve pressure as described in your
PD2K operation manual.
5. Return the system to service.
2. Engage the pins of the tool (114) with the notches
in the retainer (5) and unscrew the retainer.
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Replace a Solenoid
Replace the Color Change Board
Fuse
1. Remove electrical power from the system.
2. Remove air supply pressure from the system.
3. Remove the color change module cover (304).
NOTE: Replacing the fuse with a non-Graco fuse
voids the IS system safety approval.
4. Disconnect the two solenoid wires from
the color change board (302). See the
color change board wiring diagrams in the
Fuse
F1
Part No.
123690
Description
Fuse; 125 mA,
intrinsically safe
5. Remove the solenoid (310) from the manifold
(309).
1. Remove electrical power from the system.
2. Remove the color change module cover (304).
6. Install the new solenoid.
3. Locate fuse F1 (302a) on the color change board.
Pull the fuse away from the board.
7. Connect the two solenoid wires to the
color change board (302). See the color
change board wiring diagrams in the
4. Install the new fuse.
5. Reinstall the cover. Restore electrical power to
the system.
8. Reinstall the cover.
44
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Replace the Color Change Board
NOTICE
2. Remove the color change module cover (304).
3. Note where each cable is connected, then
disconnect all cables from the color change
board connectors.
4. Remove the seven mounting screws (303) and
the board (302).
To avoid damaging the circuit boards, wear Part
No. 112190 grounding strap on your wrist and
ground appropriately.
5. Install the new board. Reinstall the screws.
6. Reconnect the cables to the proper
connectors, as noted in step 3. See
To avoid electrical component damage, remove all
system power before plugging any connectors.
7. Reinstall the cover (304). Restore electrical
power to the system.
1. Remove electrical power from the system.
Figure 23 Control Module Repair (Non-IS Module
Shown)
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Ref.
No.
Part
No.
Description
Qty
Ref.
No.
Part
No.
Description
Qty
◆
101
102
103
24U237 BRACKET, mounting
1
2
4
115
598095 TUBE; nylon; 5/32 in. (4 mm)
OD
◆
KIT, manifold, valve
120
222200 REGULATOR, back pressure;
used on high pressure kits
only (see detail drawing); see
manual 307892
1
100157 SCREW, cap, hex head;
1/4–20 x 0.375 in. (10 mm)
104
103195 SCREW, cap, hex head;
1/4–20 x 4.0 in. (101 mm)
4
121
122
123
113070 NIPPLE; 3/8 npt x 1/4 npt; sst;
used on high pressure kits
2
1
1
105
106
107
100016 WASHER, lock; 1/4
100015 NUT, hex; 1/4–20
4
4
2
only (see detail drawing)
110290 TEE; 1/4 npt(f); sst; used on
high pressure kits only (see
detail drawing)
24N346 HOSE, fluid; 1/4 npsm (fbe);
2.5 ft (0.76 m); ptfe
◆
108
109
KIT, module, control
1
1
112564 GAUGE, pressure, fluid; used
on high pressure kits only (see
detail drawing)
15V206 CABLE, CAN; 5–pin female;
10 ft (3.05 m)
110
111
16V819 GROMMET, cable
1
1
◆ See the following tables for the part number used
in your color change kit.
24U236 TOOL, repair, valve (not
shown)
◆
114
TOOL, installation, valve (not
shown)
1
Low Pressure Non-IS Kits
Kit No.
Kit Description
Standard Valve Control Module Tool (114)
Tube Length
(115)
Manifold Kits
(102) [see
Kit (108) [see
all available
kits]
Low Pressure Non-Circulating Color Change Kits
24R915
24R916
2 color or 2
catalyst
24T458
24T557
24U239
60 ft (18.3 m)
120 ft (36.6 m)
4 color or 4
catalyst
24T460
24T558
24U239
24R917
24R918
6 color
8 color
24T462
24T464
24T559
24T560
24U239
24U239
210 ft (64.05 m)
360 ft (109.8 m)
Low Pressure Circulating Color Change Kits
24R919
24R920
24R921
24R922
2 color
4 color
6 color
8 color
24T488
24T490
24T492
24T494
24T557
24T558
24T559
24T560
24U239
24U239
24U239
24U239
60 ft (18.3 m)
120 ft (36.6 m)
210 ft (64.05 m)
360 ft (109.8 m)
333282B
47
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High Pressure Non-IS Kits
Kit No.
Kit Description
Standard Valve Control Module Tool (114)
Tube Length
(115)
Manifold Kits
(102) [see
Kit (108) [see
all available
kits]
High Pressure Non-Circulating Color Change Kits
24R959
24R960
2 color or 2
catalyst
24T648
24T557
24U240
60 ft (18.3 m)
120 ft (36.6 m)
4 color or 4
catalyst
24T650
24T558
24U240
24R961
24R962
6 color
8 color
24T652
24T654
24T559
24T560
24U240
24U240
210 ft (64.05 m)
360 ft (109.8 m)
High Pressure Acid Compatible Non-Circulating Catalyst Change Kits
24T579
24T580
2 catalyst
4 catalyst
24U182
24U183
24T557
24T558
24U240
24U240
60 ft (18.3 m)
120 ft (36.6 m)
High Pressure Circulating Color Change Kits
24R963
24R964
24R965
24R966
2 color
4 color
6 color
8 color
24T678
24T680
24T682
24T684
24T557
24T558
24T559
24T560
24U240
24U240
24U240
24U240
60 ft (18.3 m)
120 ft (36.6 m)
210 ft (64.05 m)
360 ft (109.8 m)
48
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IS Color Change Kits
Ref.
No.
Part No.
◆
Description
Qty
2
Ref.
No.
Part No.
Description
Qty
1
101
KIT, manifold, valve; . See
53 for available kits.
110
TOOL, repair, color change
valve, not shown
24U236
24R124
Low Pressure
High Pressure
103
104
105
24V351
24N346
MANIFOLD, mix, remote
HOSE, coupled, 2.5 ft.
HOSE, static mixer
Low Pressure
1
2
1
111
TOOL, installation, color
change valve, not shown
1
24U239
24U240
223547
100016
16V429
Low Pressure
High Pressure
16W564
16W563
◆
High Pressure
112
113
114
WIRE, assembly, 25 ft.
WASHER, lock
2
4
1
106
107
108
109
KIT, module, control
BRACKET, manifold
NUT, hex
1
2
4
4
16Y954
100015
CABLE, CAN, 50 ft (15.2 m);
not shown
SCREW, cap, hex
Low Pressure
104429
113469
◆ See the following tables for the part number used
in your color change kit.
High Pressure
50
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Low Pressure IS Kits
Kit No.
Kit Description
Standard Valve Man-
ifold Kits (101) [see
Control Module
Kit (106) [see
all available kits]
parts]
Low Pressure Non-Circulating Color Change Kits
24V157
24V158
24V159
24V160
24V161
24V162
24V331
24V332
24V333
24V334
24V335
24V343
24V344
24V345
24V346
1 color and 1 catalyst
2 colors and 1 catalyst
4 colors and 1 catalyst
6 colors and 1 catalyst
8 colors and 1 catalyst
12 colors and 1 catalyst
2 colors and 2 catalysts
4 colors and 2 catalysts
6 colors and 2 catalysts
8 colors and 2 catalysts
24T457 (2)
24T571
24T571
24T572
24T573
24T574
24T774
24T571
24T572
24T573
24T574
24T774
24T775
24T776
24T777
24T778
24T458, 24T457
24T460, 24T457
24T462, 24T457
24T464, 24T457
24T468, 24T369
24T458 (2)
24T460, 24T458
24T462, 24T458
24T464, 24T458
12 colors and 2 catalysts 24T468, 24T458
4 colors and 4 catalysts
6 colors and 4 catalysts
8 colors and 4 catalysts
24T460 (2)
24T462, 24T460
24T464, 24T460
12 colors and 4 catalysts 24T468, 24T460
Low Pressure Circulating Color Change Kits
24V166
24V167
24V308
24V309
24V326
24V327
24V336
24V337
24V338
24V339
24V340
24V347
24V348
24V349
24V350
1 color and 1 catalyst
2 colors and 1 catalyst
4 colors and 1 catalyst
6 colors and 1 catalyst
8 colors and 1 catalyst
12 colors and 1 catalyst
2 colors and 2 catalysts
4 colors and 2 catalysts
6 colors and 2 catalysts
8 colors and 2 catalysts
24T487 (2)
24T571
24T571
24T572
24T573
24T574
24T774
24T571
24T572
24T573
24T574
24T774
24T775
24T776
24T777
24T778
24T488, 24T487
24T490, 24T487
24T492, 24T487
24T494, 24T487
24T498, 24T487
24T488 (2)
24T490, 24T488
24T492, 24T488
24T494, 24T488
12 colors and 2 catalysts 24T498, 24T488
4 colors and 4 catalysts
6 colors and 4 catalysts
8 colors and 4 catalysts
24T490 (2)
24T492, 24T490
24T494, 24T490
12 colors and 4 catalysts 24T498, 24T490
333282B
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High Pressure IS Kits
Kit No.
Kit Description
Standard Valve Man-
ifold Kits (101) [see
Control Module
Kit (106) [see
all available kits]
parts]
High Pressure Non-Circulating Color Change Kits
24V359
24V360
24V361
24V362
24V363
24V364
24V381
24V382
24V383
24V384
24V385
24V396
24V397
24V398
24V399
1 color and 1 catalyst
2 colors and 1 catalyst
4 colors and 1 catalyst
6 colors and 1 catalyst
8 colors and 1 catalyst
12 colors and 1 catalyst
2 colors and 2 catalysts
4 colors and 2 catalysts
6 colors and 2 catalysts
8 colors and 2 catalysts
24T647 (2)
24T571
24T571
24T572
24T573
24T574
24T774
24T571
24T572
24T573
24T574
24T774
24T775
24T776
24T777
24T778
24T648, 24T647
24T650, 24T647
24T652, 24T647
24T654, 24T647
24T658, 24T647
24T648 (2)
24T650, 24T648
24T652, 24T648
24T654, 24T648
12 colors and 2 catalysts 24T658, 24T648
4 colors and 4 catalysts
6 colors and 4 catalysts
8 colors and 4 catalysts
24T650 (2)
24T652, 24T650
24T654, 24T650
12 colors and 4 catalysts 24T658, 24T650
High Pressure Circulating Color Change Kits
24V369
24V370
24V371
24V372
24V373
24V374
24V389
24V390
24V391
24V392
24V393
24V402
24V403
24V404
24V405
1 color and 1 catalyst
2 colors and 1 catalyst
4 colors and 1 catalyst
6 colors and 1 catalyst
8 colors and 1 catalyst
12 colors and 1 catalyst
2 colors and 2 catalysts
4 colors and 2 catalysts
6 colors and 2 catalysts
8 colors and 2 catalysts
24T677(2)
24T571
24T571
24T572
24T573
24T574
24T774
24T571
24T572
24T573
24T574
24T774
24T775
24T776
24T777
24T778
24T678, 24T677
24T680, 24T677
24T682, 24T677
24T684, 24T677
24T688, 24T677
24T678 (2)
24T680, 24T678
24T682, 24T678
24T684, 24T678
12 colors and 2 catalysts 24T688, 24T678
4 colors and 4 catalysts
6 colors and 4 catalysts
8 colors and 4 catalysts
24T680 (2)
24T682, 24T680
24T684, 24T680
12 colors and 4 catalysts 24T688, 24T680
52
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Valve Manifold Kits
The low pressure and high pressure valve manifold
kits listed in this section are used in both the Non-IS
and IS color valve stacks.
Low Pressure Valve Manifold Kits
Non-Circulating Valve Manifold Kits
Circulating Valve Manifold Kits
Kit No.
Series
A
Kit Description
2 valves
Kit No.
Series
A
Kit Description
2 valves
24T457
24T458
24T459
24T460
24T461
24T462
24T463
24T464
24T465
24T466
24T467
24T468
24T469
24T470
24T471
24T472
24T473
24T474
24T475
24T476
24T477
24T478
24T479
24T480
24T481
24T482
24T483
24T484
24T485
24T486
24T487
24T488
24T489
24T490
24T491
24T492
24T493
24T494
24T495
24T496
24T497
24T498
24T499
24T500
24T501
24T502
24T503
24T504
24T505
24T506
24T507
24T508
24T509
24T510
24T511
24T512
24T513
24T514
24T515
24T516
A
3 valves
A
3 valves
A
4 valves
A
4 valves
A
5 valves
A
5 valves
A
6 valves
A
6 valves
A
7 valves
A
7 valves
A
8 valves
A
8 valves
A
9 valves
A
9 valves
A
10 valves
11 valves
12 valves
13 valves
14 valves
15 valves
16 valves
17 valves
18 valves
19 valves
20 valves
21 valves
22 valves
23 valves
24 valves
25 valves
26 valves
27 valves
28 valves
29 valves
30 valves
31 valves
A
10 valves
11 valves
12 valves
13 valves
14 valves
15 valves
16 valves
17 valves
18 valves
19 valves
20 valves
21 valves
22 valves
23 valves
24 valves
25 valves
26 valves
27 valves
28 valves
29 valves
30 valves
31 valves
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
333282B
53
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Valve Manifold Kit Parts
54
333282B
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Ref.
No.
Part No.
Description
Qty
Ref.
No.
Part No.
Description
Qty
1
2
3
16P259
111450
24T441
MANIFOLD
12
13
104893
24T523
O-RING; ptfe
O-RING; chemically resistant
FITTING, fluid; 7/16–20 x 1/4
npt(m)
VALVE, for non-circulating
kits; includes item 2
14
111328
CONNECTOR, tube;
10–32(m) x 5/32 in. (4
mm) OD tube
24T442
VALVE, for circulating kits;
includes item 2
15
16
24T525
24T524
ROD, connecting; 3 in. (76
mm)
4
24R051
16N256
111457
24T521
24T522
157974
104092
PLUG, cc valve
★
5
RETAINER, nut
★
ROD, connecting; 1.5 in. (38
mm)
6
O-RING; ptfe
17
18
19
111504
557716
104644
O-RING; chemically resistant
PLUG; 7/16–20
7
PLATE, outlet, manifold
PLATE, end, manifold
WASHER, plain
8
PLUG, screw; 10–32 x 0.156
in. (4 mm)
9
10
SCREW, cap, socket head;
10–24 x 0.625 in. (16 mm)
★ See the following tables to determine the quantity
of each part in your valve manifold kit.
11
100179
NUT, hex; 10–24
Low Pressure Non-Circulating Valve Manifold Kit Part Quantities
Kit No.
Reference Numbers
1
1
2
2
3
2
3
4
5
6
7
8
9
4
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
5
6
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
7
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
3
12
3
13
3
14
2
15
0
16
3
17
1
18
2
19
0
2
2
24T457
24T458
24T459
24T460
24T461
24T462
24T463
24T464
24T465
24T466
24T467
24T468
24T469
24T470
24T471
24T472
24T473
24T474
24T475
4
4
3
4
4
3
3
0
1
5
2
3
2
3
3
4
6
6
8
8
10
4
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
5
6
7
8
9
5
6
7
8
9
4
5
6
7
8
9
0
3
3
0
0
3
3
0
0
3
3
0
0
3
3
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
6
3
3
6
6
6
6
9
9
9
9
7
6
6
4
8
9
4
8
8
5
10
10
12
12
14
14
16
16
10 10
11
10
13
12
15
14
17
16
19
18
21
20
5
10 10
12 11
12 12
14 13
14 14
16 15
16 16
18 17
18 18
20 19
20 20
11 11 10
12 12 11
13 13 12
14 14 13
15 15 14
6
6
7
7
8
16 16 15 12
17 17 16 12
18 18 17 12
19 19 18 12
20 20 19 15
21 21 20 15
8
9
18 10
18 10
20 11
20 11
9
10
10
333282B
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Kit No.
Reference Numbers
1
2
3
4
1
0
1
0
1
0
1
0
1
0
1
5
6
7
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
10
3
3
3
3
3
3
3
3
3
3
3
12
13
14
15
16
3
3
0
0
3
3
0
0
3
3
0
17
1
1
1
1
1
1
1
1
1
1
1
18
23
22
25
24
27
26
29
28
31
30
33
19
2
0
2
0
2
0
2
0
2
0
2
11
11
12
12
13
13
14
14
15
15
16
24T476
24T477
24T478
24T479
24T480
24T481
24T482
24T483
24T484
24T485
24T486
22 21
22 22
24 23
24 24
26 25
26 26
28 27
28 28
30 29
30 30
32 31
22 12
22 12
24 13
24 13
26 14
26 14
28 15
28 15
30 16
30 16
32 17
22 22 21 15
23 23 22 15
24 24 23 18
25 25 24 18
26 26 25 18
27 27 26 18
28 28 27 21
29 29 28 21
30 30 29 21
31 31 30 21
32 32 31 24
56
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Low Pressure Circulating Valve Manifold Kit Part Quantities
Kit No.
Reference Numbers
1
1
2
2
3
2
3
4
5
6
7
8
9
4
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
5
6
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
7
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
3
12
5
13
5
14
2
15
0
16
3
17
1
18
0
19
0
2
2
24T487
24T488
24T489
24T490
24T491
24T492
24T493
24T494
24T495
24T496
24T497
24T498
24T499
24T500
24T501
24T502
24T503
24T504
24T505
24T506
24T507
24T508
24T509
24T510
24T511
24T512
24T513
24T514
24T515
24T516
4
4
3
7
7
3
3
0
1
2
2
3
2
4
6
6
8
8
10
4
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
9
9
4
5
6
7
8
9
0
3
3
0
0
3
3
0
0
3
3
0
0
3
3
0
0
3
3
0
0
3
3
0
0
3
3
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
3
6
11 11
13 13
15 15
17 17
19 19
3
3
6
6
6
6
9
9
9
9
3
6
4
8
4
8
5
10
10
12
12
14
14
16
16
5
10 10
12 11
12 12
14 13
14 14
16 15
16 16
18 17
18 18
20 19
20 20
22 21
22 22
24 23
24 24
26 25
26 26
28 27
28 28
30 29
30 30
32 31
21 21 10
23 23 11
25 25 12
27 27 13
29 29 14
6
6
7
7
8
31 31 15 12
33 33 16 12
35 35 17 12
37 37 18 12
39 39 19 15
41 41 20 15
43 43 21 15
45 45 22 15
47 47 23 18
49 49 24 18
51 51 25 18
53 53 26 18
55 55 27 21
57 57 28 21
59 59 29 21
61 61 30 21
63 63 31 24
8
9
18 10
18 10
20 11
20 11
22 12
22 12
24 13
24 13
26 14
26 14
28 15
28 15
30 16
30 16
32 17
9
10
10
11
11
12
12
13
13
14
14
15
15
16
333282B
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High Pressure Valve Manifold Kits
Non-Circulating Valve Manifold Kits
Circulating Valve Manifold Kits
Kit No.
Series
A
Kit Description
2 valves
Kit No.
Series
A
Kit Description
2 valves
24T647
24T648
24T649
24T650
24T651
24T652
24T653
24T654
24T655
24T656
24T657
24T658
24T659
24T660
24T661
24T662
24T663
24T664
24T665
24T666
24T667
24T668
24T669
24T670
24T671
24T672
24T673
24T674
24T675
24T676
24T677
24T678
24T679
24T680
24T681
24T682
24T683
24T684
24T685
24T686
24T687
24T688
24T689
24T690
24T691
24T692
24T693
24T694
24T695
24T696
24T697
24T698
24T699
24T700
24T701
24T702
24T703
24T704
24T705
24T706
A
3 valves
A
3 valves
A
4 valves
A
4 valves
A
5 valves
A
5 valves
A
6 valves
A
6 valves
A
7 valves
A
7 valves
A
8 valves
A
8 valves
A
9 valves
A
9 valves
A
10 valves
11 valves
12 valves
13 valves
14 valves
15 valves
16 valves
17 valves
18 valves
19 valves
20 valves
21 valves
22 valves
23 valves
24 valves
25 valves
26 valves
27 valves
28 valves
29 valves
30 valves
31 valves
3 valves
A
10 valves
11 valves
12 valves
13 valves
14 valves
15 valves
16 valves
17 valves
18 valves
19 valves
20 valves
21 valves
22 valves
23 valves
24 valves
25 valves
26 valves
27 valves
28 valves
29 valves
30 valves
31 valves
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
24T845 (acid-
catalyzed)
A
24T846 (acid-
catalyzed)
A
5 valves
58
333282B
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Valve Manifold Kit Parts
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Ref.
No.
Part No.
16N271
111450
Description
Qty
Ref.
No.
Part No.
24T523
111328
Description
Qty
MANIFOLD, for circulating
kits
13
FITTING, fluid; 7/16–20 x
1/4 npt(m)
1
2
3
O-RING; chemically
resistant
14
CONNECTOR, tube;
10–32(m) x 5/32 in. (4
mm) OD tube
VALVE, for non-circulating
kits; includes item 2
24T581
24T582
24T583
15
16
24T729
24T728
ROD, connecting; 3.290 in.
(84 mm)
★
VALVE, for circulating kits;
includes item 2
ROD, connecting; 1.645 in.
(42 mm)
VALVE, for non-circulating,
acid compatible kits;
includes item 2
18
19
557716
104644
PLUG; 7/16–20
★
PLUG, screw; 10–32 x 0.156
in. (4 mm)
4
24R052
16N269
111457
24T725
24T726
111820
PLUG, cc valve
5
RETAINER, nut
★ See the following tables to determine the quantity
of each part in your valve manifold kit.
6
O-RING; ptfe
7
PLATE, outlet, manifold
PLATE, end, manifold
8
10
SCREW, cap, socket head;
10–24 x 0.75 in. (19 mm)
12
104893
O-RING; ptfe
High Pressure Non-Circulating Valve Manifold Kit Part Quantities
Kit No.
Reference Numbers
4
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
5
6
7
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
3
12
3
13
3
14
2
15
0
16
1
18
0
19
0
1
1
2
2
3
2
2
2
2
24T647
24T648
24T649
24T650
24T651
24T652
24T653
24T654
24T655
24T656
24T657
24T658
24T659
24T660
24T661
24T662
4
3
4
3
3
4
4
3
1
0
1
2
1
2
3
3
4
4
5
5
6
6
7
7
8
8
9
4
4
4
3
4
4
5
5
6
6
7
7
8
8
9
9
10
3
3
3
3
3
3
3
3
3
3
3
3
3
3
5
5
4
0
1
1
0
0
1
1
0
0
1
1
0
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
2
0
2
0
2
0
2
0
2
0
2
0
2
6
5
6
6
6
5
1
1
2
2
2
2
3
3
3
3
4
4
4
6
6
6
7
7
6
8
7
8
8
8
7
8
8
8
9
9
8
10
10
12
12
14
14
16
16
18
9
10
10
12
12
14
14
16
16
18
10
11
12
13
14
15
16
17
18
10
11
12
13
14
15
16
17
18
9
10
11
12
13
14
15
16
17
10
11
12
13
14
15
16
17
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Kit No.
Reference Numbers
4
0
1
0
1
0
1
0
1
0
1
0
1
0
1
1
1
5
6
7
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
12
19
20
21
22
23
24
25
26
27
28
29
30
31
32
4
13
19
20
21
22
23
24
25
26
27
28
29
30
31
32
4
14
18
19
20
21
22
23
24
25
26
27
28
29
30
31
3
15
4
5
5
5
5
6
6
6
6
7
7
7
7
8
1
1
16
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
18
0
1
0
1
0
1
0
1
0
1
0
1
0
1
1
1
19
0
2
0
2
0
2
0
2
0
2
0
2
0
2
2
2
1
2
3
9
24T663
24T664
24T665
24T666
24T667
24T668
24T669
24T670
24T671
24T672
24T673
24T674
24T675
24T676
24T845
24T846
18
20
20
22
22
24
24
26
26
28
28
30
30
32
4
18
19
20
21
22
23
24
25
26
27
28
29
30
31
3
18
20
20
22
22
24
24
26
26
28
28
30
30
32
4
10
11
11
12
12
13
13
14
14
15
15
16
16
17
3
10
10
11
11
12
12
13
13
14
14
15
15
16
2
3
6
5
6
4
6
6
5
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High Pressure Circulating Valve Manifold Kit Part Quantities
Kit No.
Reference Numbers
4
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
5
6
7
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
3
12
5
13
5
14
2
15
0
16
1
18
0
19
0
1
1
2
2
3
2
2
2
2
24T677
24T678
24T679
24T680
24T681
24T682
24T683
24T684
24T685
24T686
24T687
24T688
24T689
24T690
24T691
24T692
24T693
24T694
24T695
24T696
24T697
24T698
24T699
24T700
24T701
24T702
24T703
24T704
24T705
24T706
4
3
4
3
3
7
7
3
1
0
2
2
1
2
4
4
4
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
9
9
4
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
0
2
3
6
5
6
4
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
61
63
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
61
63
5
1
1
2
2
2
2
3
3
3
3
4
4
4
4
5
5
5
5
6
6
6
6
7
7
7
7
8
3
6
6
6
4
6
4
8
7
8
5
7
4
8
8
8
5
8
5
10
10
12
12
14
14
16
16
18
18
20
20
22
22
24
24
26
26
28
28
30
30
32
9
10
10
12
12
14
14
16
16
18
18
20
20
22
22
24
24
26
26
28
28
30
30
32
6
9
5
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
6
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
6
7
6
7
7
8
7
8
8
9
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
9
10
10
11
11
12
12
13
13
14
14
15
15
16
62
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Ref.
No.
Part
No.
Description
PANEL
Qty
Ref.
No.
Part
No.
Description
Qty
— — —
301
302
302a
303
1
1
1
6
316
317
C06061 MUFFLER
2
1
24T566 BOARD, circuit
123690 FUSE; 125 mA
115671
FITTING, connector; 1/8
npt(m) x 1/4 in. (6 mm) OD
tube
112324 SCREW, machine, pan head;
4–40 x 0.25 in. (6 mm)
318
319
320
112698 ELBOW; 1/8 npt(m) x 1/4 in.
(6 mm) OD tube
2
1
1
304
305
307
308
309
310
311
24T562 COVER
1
590332 TUBE; polyethylene; 1/4 in. (6
mm) OD
119162 CONNECTOR, 6–position
116343 SCREW, ground; M5 x 0.8
123691 HOLDER, fuse
24T563 MANIFOLD
★
1
598095 TUBE; nylon; 5/32 in. (4 mm)
OD
1
— — —
— — —
321
322
324
STRAP, tie
FERRULE
★
★
★
2
16P316 SOLENOID
★
4
114263 FITTING, connector; 1/8
npt(m) x 5/32 in. (4 mm) OD
tube
117831 SCREW, machine, pan head;
6–32 x 0.5 in. (13 mm)
312
313
103833 SCREW, machine, pan head;
10–32 x 0.375 in. (10 mm)
8
332
151395 WASHER
4
24T565 PLUG; 5/8–32; includes item
314
★
★ See the following table to determine the quantity of
each part in your control module kit.
314
315
113418 O-RING; buna-N
14
3
Parts labeled — — — are not available separately.
100139 PLUG, pipe; 1/8 npt
Non-IS Control Module Part Quantities
Find your module kit no. in the left column and the desired reference number in the top row to find the part
quantity used in your control module kit.
Kit No.
Kit
6–Position Solenoid
Plug (313) Tie Strap
(321)
Ferrule
(322)
Connector
Fitting
(324)
Description Connector (310)
(305)
24T557
24T558
24T559
24T560
2 color
4 color
6 color
8 color
2
4
6
6
6
12
8
4
4
4
4
12
20
28
36
6
10
14
18
10
14
18
4
0
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Ref.
No.
Part
No.
Description
PANEL
Qty
Ref.
No.
Part
No.
Description
Qty
2
— — —
301
302
302a
303
1
1
1
6
318
319
320
112698 ELBOW; 1/8 npt(m) x 1/4 in.
(6 mm) OD tube
24T566 BOARD, circuit
123690 FUSE; 125 mA
590332 TUBE; polyethylene; 1/4 in. (6
mm) OD
1
112324 SCREW, machine, pan head;
4–40 x 0.25 in. (6 mm)
598095 TUBE; nylon; 5/32 in. (4 mm)
OD
1
304
305
307
308
309
310
311
24U567 COVER
1
6
1
1
2
★
4
— — —
— — —
321
322
324
STRAP, tie
FERRULE
2
119162 CONNECTOR, 6–position
116343 SCREW, ground; M5 x 0.8
123691 HOLDER, fuse
15T636 MANIFOLD
★
★
109193 ELBOW, connector; 10–32
(m) x 5/32 in. (4 mm) OD tube
331
332
333
334
335
16U743 SPACER
6
1
1
3
1
16U744 PLATE, non-conductive
16U745 PLATE, ground
121324 SOLENOID
SCREW, machine, serrated
head; 10–32 x 0.5 in. (13 mm)
16M00
7
16U746 SCREW, pan-head; 4–40
312
313
103833 SCREW, machine, pan head;
10–32 x 0.375 in. (10 mm)
4
16W50
1
LABEL, instructions
121628 SCREW, self-sealing; 4–40 x
0.25 in. (6 mm)
★
339
340
341
102794 NUT, hex
7
7
7
101764 WASHER, lock
188773 WASHER, flat
315
316
317
100139 PLUG, pipe; 1/8 npt
C06061 MUFFLER
3
2
1
★ See the following table to determine the quantity of
each part in your control module kit.
115671 FITTING, connector; 1/8
npt(m) x 1/4 in. (6 mm) OD
tube
Parts labeled — — — are not available separately.
IS Control Module Part Quantities
Find your module kit no. in the left column and the desired reference number in the top row to find the part
quantity used in your control module kit.
Kit No.
24T571
24T572
24T573
24T574
24T774
Kit
Solenoid
(310)
Plug (313)
Tube (320)
Ferrule (322) Connector
Fitting (324)
Description
2 color and 2
catalyst
6
24
20
16
12
4
30 ft (9.1 m)
12
6
4 color and 2
catalyst
8
40 ft (12.2 m) 16
50 ft (15.2 m) 20
60 ft (18.3 m) 24
80 ft (24.4 m) 32
8
6 color and 2 10
catalyst
10
12
16
8 color and 2 12
catalyst
12 color and 16
2 catalyst;
13–24 color
24T775
4 color and 4 10
catalyst
16
50 ft (15.2 m) 20
10
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Kit No.
24T776
24T777
24T778
Kit
Solenoid
(310)
Plug (313)
Tube (320)
Ferrule (322) Connector
Fitting (324)
Description
6 color and 4 12
catalyst
12
8
60 ft (18.3 m) 24
70 ft (21.3 m) 28
90 ft (27.4 m) 36
12
14
18
8 color and 4 14
catalyst
12 color and 18
4 catalyst;
13–30 color
0
24T779
13–18 color
6
24
30 ft. (9.1 m) 12
6
68
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Expansion Kits
To add colors/catalysts, order the correct Non-IS Expansion Kit. Also order the corresponding IS Expansion
Non-IS Expansion Kits
The following kits are available to add color valves in a non-IS area. Order a kit without a manifold if you have
room for a valve on an existing manifold. Order a kit with a manifold if all ports on your existing manifolds have
Low Pressure Expansion Kits
High Pressure Expansion Kits
Kit No.
Kit Description
Kit No.
Kit Description
Without Manifold
24T443
Without Manifold
24T584
One non-circulating valve
(replaces a plug). Includes valve,
solenoid, fittings, and tubing.
One non-circulating valve
(replaces a plug). Includes valve,
solenoid, fittings, and tubing.
24T444
One circulating valve (replaces a
plug). Includes valve, solenoid,
fittings, and tubing.
24T585
One circulating valve (replaces a
plug). Includes valve, solenoid,
fittings, and tubing.
With Manifold
24T445
With Manifold
24T586
Manifold with one non-circulating
valve. Includes valve, plug,
solenoid, fittings, and tubing.
Manifold with one non-circulating
valve. Includes valve, plug,
solenoid, fittings, and tubing.
24T446
24T447
24T448
Manifold with one circulating valve.
Includes valve, plug, solenoid,
fittings, and tubing.
24T587
24T588
24T589
Manifold with one circulating valve.
Includes valve, plug, solenoid,
fittings, and tubing.
Manifold with two non-circulating
valves. Includes valves, solenoids,
fittings, and tubing.
Manifold with two non-circulating
valves. Includes valves, solenoids,
fittings, and tubing.
Manifold with two circulating
valves. Includes valves, solenoids,
fittings, and tubing.
Manifold with two circulating
valves. Includes valves, solenoids,
fittings, and tubing.
High Pressure Acid-Compatible Expansion Kits
Kit No.
Kit Description
Without Manifold
24T590
One non-circulating acid-
compatible valve (replaces a
plug). Includes valve, solenoid,
fittings, and tubing.
With Manifold
24T591
Manifold with one non-circulating
acid-compatible valve. Includes
valve, plug, solenoid, fittings, and
tubing.
24T592
Manifold with two non-circulating
acid-compatible valves. Includes
valves, solenoids, fittings, and
tubing.
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IS Expansion Kits
The following kits are available to add color valves in an IS area. Order a kit without a manifold if you have
room for a valve on an existing manifold. Order a kit with a manifold if all ports on your existing manifolds have
Low Pressure Expansion Kits
High Pressure Expansion Kits
Kit No.
Kit Description
Kit No.
Kit Description
Without Manifold
24T449
Without Manifold
24T712
One non-circulating valve
(replaces a plug). Includes valve,
IS solenoid, fittings, and tubing.
One non-circulating valve
(replaces a plug). Includes valve,
IS solenoid, fittings, and tubing.
24T450
One circulating valve (replaces a
plug). Includes valve, IS solenoid,
fittings, and tubing.
24T713
One circulating valve (replaces a
plug). Includes valve, IS solenoid,
fittings, and tubing.
With Manifold
24T451
With Manifold
24T714
Manifold with one non-circulating
valve. Includes valve, plug, IS
solenoid, fittings, and tubing.
Manifold with one non-circulating
valve. Includes valve, plug, IS
solenoid, fittings, and tubing.
24T452
24T453
24T454
Manifold with one circulating valve.
Includes valve, plug, IS solenoid,
fittings, and tubing.
24T715
24T716
24T717
Manifold with one circulating valve.
Includes valve, plug, IS solenoid,
fittings, and tubing.
Manifold with two non-circulating
valves. Includes valves, IS
solenoids, fittings, and tubing.
Manifold with two non-circulating
valves. Includes valves, IS
solenoids, fittings, and tubing.
Manifold with two circulating
valves. Includes valves, IS
solenoids, fittings, and tubing.
Manifold with two circulating
valves. Includes valves, IS
solenoids, fittings, and tubing.
High Pressure Acid-Compatible Expansion Kits
Kit No.
Kit Description
Without Manifold
24T718
One non-circulating acid-
compatible valve (replaces a
plug). Includes valve, IS solenoid,
fittings, and tubing.
With Manifold
24T719
Manifold with one non-circulating
acid-compatible valve. Includes
valve, plug, IS solenoid, fittings,
and tubing.
24T720
Manifold with two non-circulating
acid-compatible valves. Includes
valves, IS solenoids, fittings, and
tubing.
70
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Dimensions
Figure 24 Non-IS Control Module
A
B
C
D
E
F
11.30 in. (1478
mm)
7.67 in. (195
mm)
9.8 in. (249 mm)
5.70 in. (145
mm)
0.31 in. (8 mm)
5.80 in. (147
mm)
Figure 25 IS Control Module
A
B
C
D
E
F
16.57 in. (421
mm)
8.22 in. (209
mm)
15.07 in. (383
mm)
6.70 in. (170
mm)
0.31 in. (8 mm)
4.52 in. (115
mm)
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Figure 26 Manifold Mounting Bracket, Non-IS
T
U
V
3.84 in. (98
mm)
11.44 in. (291
mm)
0.312 in. (8
mm) diameter
72
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Figure 27 IS Valve Manifold Bracket
A
B
C
D
E
F
5.63 in (168
mm)
1.92 in (49 mm) 3.35 in (85 mm) 1.80 in (46 mm) 1.32 in (34 mm)
0.65 in. (17
mm)
G
H
J
K
L
M
0.24 in (6 mm) 1.00 in (25 mm) 0.88 in (22 mm) 0.40 in (10 mm) 0.40 in (10 mm) 0.11 in (3 mm)
N
P
4 x 0.28 in (7
mm)
2 x 0.41 in (10
mm)
333282B
73
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Figure 28 Remote Mix Manifold Bracket
A
B
C
D
E
F
3.00 in (76 mm) 1.45 in (37 mm) 2.00 in (51 mm) 1.05 in (27 mm) 2.50 in (64 mm) 0.50 in (13 mm)
G
H
J
K
1.25 in (32 mm)
0.11 (3 mm)
4 x 0.22 in (6
mm)
2 x 0.41 (10
mm)
74
333282B
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Technical Data
Color Change Kits
U.S.
Metric
Maximum fluid working
pressure:
Low pressure kits
High pressure kits
Maximum working air
pressure:
300 psi
1500 psi
100 psi
2.1 MPa, 21 bar
10.5 MPa, 105 bar
0.7 MPa, 7.0 bar
Air supply:
85–100 psi
0.6–0.7 MPa, 6.0–7.0 bar
Viscosity range of fluid:
Fluid inlet size:
Fluid outlet size:
Air inlet size:
20–5000 centipoise
1/4 npt(f)
1/4 npt(f)
5/32 in. OD tube
4 mm OD tube
Wetted parts:
Valve manifold Glass-filled polyphenylene sulfide, 316 SST, PTFE, chemically resistant o-rings
Valve
See valve manual 332454.
333282B
75
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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
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original Instructions. This manual contains English. MM 333282
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Revision B, September 2014
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