Graco Fluid Automation F4 Series User manual

3A3103A
EN
Kits - Accessories
Fluid Automation™
F4 Series
Kits and accessories for use with Fluid Automation F4 series systems.
For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
For use with models:
F4-5
F4-55
Refer to the Fluid Automation F4 Series Setup-Operation
manual 335028 for maximum working pressure and
model information.
Important Safety Instructions
Read all warnings and instructions in this
manual and the Fluid Automation F4 Series
Setup-Operation manual 335028. Save all
instructions.

Related Manuals
23A3103A
Related Manuals
Refer to Fluid Automation F4 Series Setup-Operation
manual 335028 for the complete list of related manuals.
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 6
F4-55 Caster Kit, 24X218 . . . . . . . . . . . . . . . . . . 7
Dual Press Kit, 25A102 . . . . . . . . . . . . . . . . . . . . 7
Second Press Cable Kit, 25A106 . . . . . . . . . . . . 9
Barrel Mixing Stacks Supported . . . . . . . . . . . . 10
Material In-line Filters . . . . . . . . . . . . . . . . . . . . 12
Material Regulators . . . . . . . . . . . . . . . . . . . . . . 13
Colorant Tank Kits . . . . . . . . . . . . . . . . . . . . . . 14
Color Flow Meter Kits . . . . . . . . . . . . . . . . . . . . 16
Color Injector Kit, 25A108 . . . . . . . . . . . . . . . . . 16
5-Gallon Pail Girdle, 25A160 . . . . . . . . . . . . . . 17
Continuous Low Level Sensor Kits . . . . . . . . . . 18
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4-55 Caster Kit, 24X218 . . . . . . . . . . . . . . . . . 20
Dual Press Kit, 25A102 . . . . . . . . . . . . . . . . . . . 21
Second Press Cable Kit, 25A106 . . . . . . . . . . . 22
Barrel Mixing Stack Kit, 24R681 . . . . . . . . . . . . 23
Barrel Mixing Stack Kit, 25A169 . . . . . . . . . . . . 25
Barrel Mixing Stack Kit, SK556 and SK556-2A . 27
Manifold/Gun Assembly for Barrel Mixer Stacks,
SA914-3A/-5A . . . . . . . . . . . . . . . . . . . . . . . 29
Solenoid Block for Barrel Mixer Stacks, SK579/-2A
31
Colorant Tank Kit, 25A104 . . . . . . . . . . . . . . . . 32
Colorant Tank Kit, 25A105 . . . . . . . . . . . . . . . . 34
Color Flow Meter Kits, 25A103 and 25A161 . . . 36
Color Injector Kit, 25A108 . . . . . . . . . . . . . . . . . 37
5-Gallon Pail Girdle, 25A160 . . . . . . . . . . . . . . 40
Continuous Level Sensor Kit, 25A100 . . . . . . . 41
Continuous Level Sensor Kit, 25A101 . . . . . . . 42
Filters and Regulators . . . . . . . . . . . . . . . . . . . . 43
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 46

Warnings
3A3103A 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of Fluid Automation F4 Series
equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to proce-
dure-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.
WARNINGWARNINGWARNING
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded.Improper grounding, setup, or usage of the system can cause elec-
tric shock.
• Turn off and disconnect power cord before servicing equipment.
• Connect only to grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors
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.

Warnings
43A3103A
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent
flowing through the equipment can cause static sparking. 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).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• 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.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static 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.
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 manu-
facturer’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.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read SDSs 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.
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. 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
WARNINGWARNINGWARNING
WARNING

Warnings
3A3103A 5
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or prop-
erty damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Do not use chlorine bleach.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material sup-
plier for compatibility.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
WARNINGWARNINGWARNING
WARNING

Installation
63A3103A
Installation
Pressure Relief Procedure
NOTE: There is pressure on each side of both the A and
B dosing valves. Pressure must be relieved on the pump
side and the stack side of the dosing valves.
1. To relieve pressure at the pump, turn off the system
air slider valve.
2. Open the prime ball valves for both the A and B
pumps.
3. To relieve pressure on the side leading out to the
stack from the dosing valves, ensure the material
outlet valves are open on the A and B side.
4. Open the ratio check valve on both the A and B side
to relieve pressure.
NOTE: This procedure relieves pressure from the entire
system.
NOTICE
Apply POLY-TEMP®ceramic tape or equivalent to all
National Pipe Threads (NPTs) when installing.
Follow the Pressure Relief Procedure
whenever you see this symbol.
The F4 Series 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 when you stop dispensing
and before cleaning, checking, or servicing the
equipment.
NOTICE
An empty container should always be placed under the
prime valve and the ratio check valve openings before
using them to keep material from dispensing onto the
machine.
Prime Ball
Valve
Material Outlet Valves
Ratio Check Valves

Installation
3A3103A 7
F4-55 Caster Kit, 24X218
This kit is for attaching casters to model F4-55.
1. Lift the machine until it is at least 3 in. (8 cm) off the
floor.
2. Align the four holes in the white bracket with the
holes on the caster.
3. Mount the caster to the bracket by inserting four of
the hex screws included in the kit through the top of
the bracket and securing them to the caster under-
neath with four hex nuts.
4. Torque the nuts to 30-35 ft-lbs (41-47 N•m).
5. Fasten the bracket to the base frame using four of
the hex screws.
6. Torque the hex screws to 30-35 ft-lbs (41-47 N•m).
7. Repeat steps 2-6 for the remaining three casters.
Dual Press Kit, 25A102
This kit is needed when using a second press with the
F4-5 and F4-55 machines.
NOTE: The kit contains one material outlet ball valve.
You need to use the outlet ball valve that is already
installed on the machine with the dual press kit.
1. Remove the material outlet ball valve and adapter
fitting from the machine where you are installing the
dual press kit.
NOTICE
Injury may occur if the machine is lifted and not
secured to prevent falling. Rest the machine on
stands or blocks while installing the caster kit.
Material Outlet
and Adapter
Ball Valve

Installation
83A3103A
NOTE: Apply tape to all male threads as needed.
2. Attach the valve and the adapter to the dual press
kit.
3. Attach the dual press kit to the material outlet con-
nection on the machine.
4. Tighten all connections.
5. Connect the material hoses to the dual press kit.
The material hose connections are JIC-12 flared
connections.
NOTE: Do not connect the material hoses to the barrel
mixing stacks until after the pumps and material lines
have been primed.
This kit includes a 3/8 in. air line tee that needs to be
installed at the machine’s air line outlet port when con-
necting the air lines to the stacks. See Barrel Mixing
Stacks Supported on page 10 for more information.
Location of air line outlet port on the F4-5.
Location of air line outlet port on the F4-55.

Installation
3A3103A 9
Second Press Cable Kit, 25A106
This kit contains cables for making connections from the
electronic enclosure to the barrel mixing stack and the
press when using a second press with the F4-5 and
F4-55 machines.
1. Connect the press cable to the electronic enclosure
at the connection marked Press 2.
2. Refer to the Fluid Automation F4 Series
Setup-Operation manual 335028 for information
about connecting the cable to the press.
3. Connect the cable for the barrel mixing stack to the
electronic enclosure at the connection marked
Stack 2.
4. Connect the splitter cord to the stack’s solenoid
block at the two outer connections (A and B).
Connection at Press
Connection at
Electronic
Enclosure
Connection at
Electronic
Enclosure
Connection at Stack
Press Cable Barrel Mixing
Stack Cable
Cable Connects Here
BA
C1

Installation
10 3A3103A
Barrel Mixing Stacks Supported
There are three models of barrel mixing stacks available
for use with the Fluid Automation F4 Series.
The stacks come assembled with the four 1/4 in. air line
tubes and the solenoid block already attached.
Barrel Mixing Stack Kit, 24R681
Barrel Mixing Stack Kit, 25A169
Barrel Mixing Stack Kit, SK556
SK556-2A Option
Barrel mixing stack SK556 has one option available for
a second color injector solenoid on the solenoid block.
The installation steps are the same on all models of the
barrel mixing stacks. Mounting the stack onto the press
will vary depending on the type of press being used.
NOTE: For information about using the in-line filters or
the material regulator accessories as part of the barrel
mixing stack installation, refer to those sections in this
manual.
1. Although the stack comes with the solenoid block
already mounted it, if you need to replace or rein-
stall it, ensure that is mounted on the opposite side
of the stack from the gauge faces.

Installation
3A3103A 11
2. Run the 3/8 in. air line tubing included with the kit
from the machine to the stack and connect it to the
air inlet on the stack. If two stacks are being used
with a dual press setup, use the 3/8 air line tee
included with the dual press kit (25A102) for the
connection at the machine. See page 7 for informa-
tion about the dual press kit.
3. The 1/4 in. air line tubes are already connected at
the stack. To replace or reinstall the air line tubes,
connect them as follows (when looking at the side of
the stack opposite from the gauge faces):
• Connect the air line tubes from the forward sole-
noid ports to the two closer fittings.
• Connect the air line tubes from the back ports to
the two fittings at the ends of the stack.
4. After the pumps and material lines have been
primed, connect both the A and B material outlet
hoses to the stack.
NOTE: See the Fluid Automation F4 Series Setup-Oper-
ation manual 335028 for information about priming the
pumps and material lines.
5. Connect the cables from the electronic enclosure to
the solenoids as shown below. Always use the
Stack 1 connection at the electronic enclosure if
only using one press.
NOTE: The solenoid block on barrel mixing stack
SK556-2A has an extra solenoid for a second color
injector (C2). Connect the cable from Color 2 on the
electronic enclosure to the C2 connection.
NOTE: Each of the stacks have push-to-connect fittings
to circulate fluid for presses that use chillers.
Stack Air Inlet
Material Line Connections
Stack Cables
Color 1 Cable
BA
C1

Installation
12 3A3103A
Material In-line Filters
Two in-line filter options are offered for the F4-5 and
F4-55. These are installed between the barrel mixing
stack and the press. They filter the material coming from
the stack to help prevent clogging.
In-line Filter, SA925-1A
This filter is for a 3/4 in. npt connection. If a material reg-
ulator is used, the filter should be installed between the
stack and the regulator.
In-line Filter, SA926-1A
This filter is for a 1/2 in. npt connection. If a material reg-
ulator is being used, the filter should be installed
between the stack and the regulator.
Top of Filter
Here
Stack Connects
Bottom of Filter
To Press
Top of Filter
Stack Connects Here
Bottom of Filter
To Press

Installation
3A3103A 13
Material Regulators
Material regulators help to reduce pressure fluctuations
and provide a more consistent material feed pressure
into the press. Two regulator options are offered for the
F4-5 and F4-55. The regulator is installed between the
barrel mixing stack and the press. If an in-line filter is
used, the regulator is installed after (below) the filter.
The input line is connected to the port marked IN and
the output line is connected to the port marked OUT.
Material Regulator, SA920
This regulator is for a 1/2 in. npt connection.
Material Regulator, SA921
This regulator is for a 3/4 in. npt connection.
Both kits include a gauge for monitoring pressure and a
ball valve for bleeding the line, if needed. The regulator
has an adjustment that allows you to manually increase
or decrease output pressure.
Turn the adjustment clockwise to increase pressure and
counterclockwise to decrease pressure.
NOTE: The regulators have push-to-connect fittings to
circulate fluid for press configurations that use chillers.
Pressure Adjustment

Installation
14 3A3103A
Colorant Tank Kits
There are two sizes of colorant tanks available, one for
the F4-5 and one for the F4-55.
Colorant Tank Kit, 25A104
This colorant tank is for use with the F4-5 and holds up
to 3 liters (3 qt.) of color material.
1. To mount the tank to the F4-5, remove two of the
existing bolts on a ram cylinder and attach the colo-
rant tank bracket using the two screws provided in
the kit.
2. Connect the tank to the bracket using the screw and
nut provided in the kit.
3. Ensure all screws are tight to secure the tank.
Colorant Tank Kit, 25A105
This colorant tank is for use with the F4-55 and holds up
to 11 liters (3 gal.) of color material.
1. To mount the tank to the F4-55, attach the white
tank bracket to a ram cylinder using the four hex
screws included in the kit.
Bracket
White Tank Bracket
Tank Mounting Bracket

Installation
3A3103A 15
2. Attach the tank mounting bracket to the white tank
bracket using two socket head screws included in
the kit.
3. Ensure all screws are tight to secure the tank.
4. Attach the colorant tank to the mounting bracket
using two socket head screws included in the kit.
Air Line and Color Material Line
Connections
The air line and material line connections are handled
the same way for both tank kits.
1. At the machine, remove the 3/8 in. plug from one of
the air line connections and replace it with the 3/8 in.
x 1/4 in. reducer included in the kit.
2. Connect the 1/4 in. tubing that is included with the
kit to the reducer at the machine.
3. Connect the other end of the 1/4 in. tubing to the
colorant tank air regulator on the top of the tank.
4. Connect the color material line to the JIC-6 connec-
tor at the bottom of the tank.
NOTE: The connection for the material line depends on
if you are using a color flow meter or not. See the sec-
tions on the color flow meter and color injector on page
16 to complete installation.
Tank Air Line Connection
Material Line Connection

Installation
16 3A3103A
Color Flow Meter Kits
The color flow meter provides feedback to the system
about the flow of the color material and automatically
adjusts to maintain the color setpoint, based on the
feedback and the settings in the Advanced Display Mod-
ule (ADM).
NOTE: There are two color flow meter kits available for
use with the F4 Series. Kit 25A103 can be used for most
color materials. Kit 25A161 should be used for high vis-
cosity material.
NOTE: See the Fluid Automation F4 Series Setup-Oper-
ation manual 335028 for information about calibrating
the color flow meter and color injector.
1. Connect the flow meter to the colorant tank’s mate-
rial line connection at the bottom of the tank. See
Colorant Tank Kits on page 14.
2. Connect the color material line to the outlet connec-
tion on the flow meter.
3. Connect the cable included with the color flow meter
kit to the cable connection on the flow meter.
4. Connect the other end of the cable to the electronic
enclosure at one of the Color F/M connections.
NOTE: Always use Color F/M 1 if you are only using one
press. Color F/M 2 can be used for the second connec-
tion in a dual press configuration, or if two injectors are
used on a single press.
Color Injector Kit, 25A108
The color injector connects to the barrel mixing stack
and is used to add color to the silicone material so it can
be mixed in the stack prior to being dispensed by the
press.
1. Attach the color material line from either the colorant
tank or the color flow meter (depending on the con-
figuration) to the color injector using the quick dis-
connect. The disconnect has a check mechanism
on both sides to prevent colorant from pouring out
when not attached.
2. Connect the 1/4 in. air line tubes from the color
injector to the injector solenoid on the stack.
Cable to
Electronic
Enclosure
Inlet
Connection
Outlet
Connection
Inject Color Air Hose Connection
Retract Color Injector Air Hose Connection
Color Material
Line
Inject Color Air Hose
Connects Here
Retract Injector Air Hose
Connects Here

Installation
3A3103A 17
3. Connect the cable included with the kit to the stack’s
solenoids at C1.
4. Connect the other end of the cable to the electronic
enclosure at the Color 1 connection.
5. Mount the color injector onto the stack. (Stack
24R681 shown.) Apply ceramic tape to the npt
threads on the color injector.
5-Gallon Pail Girdle, 25A160
This is intended for use with the F4-55 machine. The
pail girdle is placed around 5-gallon pails that are used
to contain material dispensed from the machine. The
pail girdle reinforces the pail to help keep it from crack-
ing or breaking when filling with material.
Stack Cables
Color 1 Cable
BA
C1

Installation
18 3A3103A
Continuous Low Level Sensor
Kits
The continuous low level sensors are designed to mea-
sure the amount of material left in the drums and pro-
vide feedback to the system. The material ratio can then
be adjusted so the drums are emptied at the same time.
Continuous Low Level Sensor, 25A100
This sensor kit is for the F4-55. It includes two sensors,
each with a bracket and hardware for mounting the sen-
sors to the machine. This kit also includes a cable for
connecting each sensor to the continuous low level
cables running from the electronic enclosure.
1. Remove the hex nut from the bolt on the end of the
ram beam nearest to the electronic enclosure.
2. Mount the sensor with the bracket as shown below
and attach and tighten the nut until secure.
3. Cables from the electronic enclosure are run
through the cable and hose guide. Look for the
cable marked E coming from the guide and connect
it to the cable included with the kit.
4. Adjust the sensor’s laser beam to target the
machine’s air line tie supports.
5. Repeat these steps for the other sensor. To ensure
accurate readings, mount the sensors so that there
are no obstructions in the way.
Do not install these sensors while the machine is
operating or when air is supplied to the system.
Removing the hex nut from the ram beam while the
machine is operating could cause personal injury or
damage the machine.
Cables from
the Electronic
Enclosure
Cable and
Hose Guide

Installation
3A3103A 19
Continuous Low Level Sensor, 25A101
This sensor kit is for the F4-5 and includes two sensors,
each with a bracket for mounting to the machine and
hardware for attaching the bracket.
These sensors are mounted on the ram frame behind
the ADM and light tower.
1. Mount the sensor with the bracket as shown below
and use the hardware included in the kit to attach it.
2. Cables from the electronic enclosure are run
through the cable and hose guide. Look for the
cable marked E coming from the guide and connect
it directly to the low level sensor.
3. Adjust the sensor’s laser beam to target the
machine’s ram tie bar bracket.
4. Repeat these steps for the other sensor. To ensure
accurate readings, mount the sensors so that there
are no obstructions.
E Cable from
Electronic
Enclosure
Cable and
Hose Guide
Cables from
the Electronic
Enclosure

Parts
20 3A3103A
Parts
F4-55 Caster Kit, 24X218
FIG. 1: Casters
Ref Part Description Quantity
1 24X217 BRACKET, caster, white 4
2 121495 CASTER, swivel, w/brake, 800 lbs 4
3 127048 SCREW, machine, hex, flange, m10 x1.5 x 25 32
4 127076 NUT, hex, flange, serrated, m10 16
3
1
2
4