SERVICE MANUAL
EN

II2G
HGB-509 / HGB-510 / HGB-609 FLUID REGULATORDESCRIPTION
Manually adjusted or remote air pressure
controlled, these fluid regulators canprovide material at constant pressurefor one or two spray guns, using
stainless steel ball valve and spring,“Perlast” valve seat. Especially design for
application with low paint viscosity andneeding accurate fluid flow regulation(Low hysteresis level).

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Manual adjustment key

B

SpringC

Diaphragm assembly

D

Ball valve

E

Fluid inlet

F

Fluid outlet

G

Pneumatic air command

H

Flushing air commandJ

Piston & adjusting washer

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EN
Product Description / Object of Declaration:

Fluid Regulator - HGB-509, HGB-510, HGBR-510, HGB-609,
HGB-609-X-B38, HGBR-609, HGBR-609-B

This Product is designed for use with:

Solvent & Waterbased Materials

Suitable for use in hazardous area:

Zone 1/Zone 2

Protection Level:

Ex h IIB 80°C Gb X

Notified body details and role:

Element Materials Technology Rotterdam B.V. (2812)
Lodging of ATEX Technical file

This Declaration of Conformity / Incorporation is issued
under the sole responsibility of the manufacturer:

Carlisle Fluid Technologies Inc.
16430 N Scottsdale
Scottsdale, AZ 85254

Representative authorised to compile the technical file Sales and Marketing Director. CFT UK Ltd
1 Avenue de Lattre de Tassigny
94736 Nogent, Cedex. FranceEU Declaration of Conformity

This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:
Machinery Directive 2006/42/EC
ATEX Directive 2014/34/EU
by complying with the following statutory documents and harmonised standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN ISO 80079-36:2016 Explosive Atmospheres- Part 36:Non Electrical equipment for explosive atmospheres-Basic
methods and requirements.
EN 1127-1:2019 Explosive atmospheres - Explosion prevention - Basic concepts

Providing all conditions of safe use / installation stated within the product manuals have been complied with and also installed inaccordance with any applicable local codes of practice.
Signed for and on behalf ofCarlisle Fluid Technologies:

F. A. Sutter Executive President: Engineering andOperations, Scottsdale, AZ, 85254. USA

Document Part No.

20/9/234-3194R-4 EN

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Product Description / Object of Declaration:

Fluid Regulator - HGB-509, HGB-510, HGBR-510, HGB-609,
HGB-609-X-B38, HGBR-609, HGBR-609-B

This Product is designed for use with:

Solvent & Waterbased Materials

Suitable for use in hazardous area:

Zone 1/Zone 2

Protection Level:

Ex h IIB 80°C Gb X

Approved body details and role:

Element Materials Technology Warwick Ltd. UK. (0891)
Lodging of UKEX Technical file

This Declaration of Conformity / Incorporation is issued
under the sole responsibility of the manufacturer:

Carlisle Fluid Technologies Inc.
16430 N Scottsdale
Scottsdale, AZ 85254



UKCA Declaration of Conformity

This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:

Supply of Machinery (Safety) Regulations 2008
Equipment and Protective Systems Intended for use in Potentially Explosive Atmospheres Regulations 2016
by complying with the following statutory documents and designated standards:
BS EN ISO 80079-36:2016 Explosive Atmospheres- Part 36:Non Electrical equipment for explosive atmospheres-Basic
methods and requirements.
BS EN 1127-1:2019 Explosive atmospheres - Explosion prevention - Basic concepts

Providing all conditions of safe use / installation stated within the product manuals have been complied with and also installed inaccordance with any applicable local codes of practice.
Signed for and on behalf ofCarlisle Fluid Technologies:

F. A. Sutter Executive President: Engineering andOperations, Scottsdale, AZ, 85254. USA

Document Part No.

20/9/23

EN

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In this part sheet, the words WARNING, CAUTION and NOTE are used toemphasize important safety information as follows:!

! CAUTIONNOTE

Hazards or unsafe practices which
could result in minor personal injury,
product or property damage.

Important installation, operation or
maintenance information.

WARNING

Hazards or unsafe practices which
could result in severe personal
injury, death or substantial property
damage.

!

WARNING

Read the following warnings before using this equipment.
READ THE MANUAL
Before operating finishing equipment, read and understand allsafety, operation and maintenance information provided in theoperation manual.

AUTOMATIC EQUIPMENT
Automatic equipment may start suddenly without warning.

WEAR SAFETY GLASSES
Failure to wear safety glasses with side shields could result inserious eye injury or blindness.

INSPECT THE EQUIPMENT DAILY
Inspect the equipment for worn or broken parts on a daily basis.
Do not operate the equipment if you are uncertain about its
condition.

DE-ENERGIZE, DEPRESSURIZE, DISCONNECT AND LOCKOUT ALL POWER SOURCES DURING MAINTENANCE
Failure to De-energize, disconnect and lock out all power supplies
before performing equipment maintenance could cause serious
injury or death.
OPERATOR TRAINING
All personnel must be trained before operating finishingequipment.

NEVER MODIFY THE EQUIPMENT
Do not modify the equipment unless the manufacturer provides
written approval.

KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT
IN CASE OF AN EMERGENCY

EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture,malfunction, or start unexpectedly and result in serious injury.

PRESSURE RELIEF PROCEDURE
Always follow the pressure relief procedure in the equipment
instruction manual.

KEEP EQUIPMENT GUARDS IN PLACE
Do not operate the equipment if the safety devices have been
removed.

PROJECTILE HAZARD
You may be injured by venting liquids or gases that are released
under pressure, or flying debris.

NOISE HAZARD
You may be injured by loud noise. Hearing protection may berequired when using this equipment.

HIGH PRESSURE CONSIDERATIONHigh pressure can cause serious injury. Relieve all pressure before
servicing. Spray from the spray gun, hose leaks, or ruptured
components can inject fluid into your body and cause extremely
serious injury.

PINCH POINT HAZARD
Moving parts can crush and cut. Pinch points are basically any
areas where there are moving parts.

STATIC CHARGE
Fluid may develop a static charge that must be dissipated throughproper grounding of the equipment, objects to be sprayed and allother electrically conductive objects in the dispensing area. Improper
grounding or sparks can cause a hazardous condition and result in
fire, explosion or electric shock and other serious injury.

PACEMAKER WARNING
You are in the presence of magnetic fields which may interferewith the operation of certain pacemakers.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE OPERATOR OF THE EQUIPMENT.
FOR FURTHER SAFETY INFORMATION REGARDING THIS EQUIPMENT, SEE THE GENERAL EQUIPMENT SAFETY BOOKLET (77-5300).

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SPECIFICATIONSType Reg

Order number

Thread
Inlet

Inlet pressure
min-max.bar

OutletManometerbar

2 – 12,5

5

13

No

HGB-609-1.2-B38

1 – 8

1,2

8,3

No

2 – 12,5

5

13

No

3 – 15

9

13No

HGB-609-1.2-R38

1 – 8

1,2

8,3

0 – 2,5

HGB-609-5-R38

2 – 12,5

5

13

0 – 6

HGB-609-9-R38

3 – 159

13

0 – 102 – 1515

1,6 (Tip 1,1mm)

No

1 – 157

1,3 (Tip 1,1mm)

No

HGB-609-9-B38

Female
3/8

Male
3/8

HGB-510-R1
HGB-510-R2
Pneumatic
Adjustment

Fluid flow
maximum
L/min

HGB-509-5-R38

HGB-609-5-B38
Manual Spring

Outlet pressure
max.barFemale1/4

Female1/4

HGB-510-R4

1 – 15

40,8 (Tip 1,1mm)

No

HGB-510-R1-CO

2 – 1515

1,6 (Tip 1,1mm)

No

1 – 157

1,3 (Tip 1,1mm)

No

1 – 15

40,8 (Tip 1,1mm)

No

HGB-510-R2-CO

Male
3/8

Female3/8

HGB-510-R4-CO

ALL MODELS
Ambient Temperature Range:
0° – 50°C (32° – 122°F)

Fluid Temperature Range:
0° – 80°C (32° – 176°F)

Maximum Continuous Fluid Temperature:
60°C (140°F)

All the fluid passages are in stainless steel, membrane in PTFE, coverin aluminum nickel treatment for manual model or anodized for remote
air control.

•C onnect the regulated fluid line, to supply one or two spraygun, side port of the regulator at the ¼’’ BSP or 3/8’’ NPS/BSP
universal (See on page 11 depend of version used).

The regulators HGB-609 are equipped with stainless steel tee and riser
tube and a manometer. The tightness of these connections ought to be
perfect so to protect the manometer.

Swivel connector female is used for “CO” version on remotecontrol.

See drawings on « Accessories ».
IMPORTANT: These regulators may be used with mostcommon coating and finishing materials. However, there are
not designed for use with highly corrosive materials whichhave such characteristics, it must be expected that frequentand thorough cleaning will be required and/or the necessity
for replacement of parts will be increased.

INSTALLATION•T he regulators must be fitted in horizontal position to remove
heavy fluid particle deposit. The riser tube for manometer must
be in vertical position. The manometer will be protected by air
staying into the top of the riser tube. A good sealing ought to bedone on the connectors so to remove any air leakage to protect
the manometer.

•T he regulator must be earthed to dissipate any electrostatic
charge which may be created by fluid or air flows. This can beachieved in using one of the screw ref 3A or 3B.
Electrical bond from the regulator to earth should be checkedwith an ohmmeter.
A resistance of less than 106 Ohms is recommended.
•A ssume that during the installation, the regulator will filled
completely the cavity under the diaphragm, this is to obtainthe full accurate regulation specially in use at lower fluid flow
delivery.

! CAUTION
It is recommended that at the initial installation thematerial supply line should not be flushed through theregulator because pipe compound chips, scale, etc. may
lodge on the valve seat USE AN IN LINE FILTER.

•C onnect the fluid supply line, coming from pump or pressure
feed tank, under the regulator at the ¼’’ BSP or 3/8’’ NPS/BSP
universal (See on page 11 depend of version used).

OPERATION
Manual regulator
Fluid pressure adjustment is done with the specific manual key.
Insert the square side key into the central top hole of the regulator
manual. See Fig A
Screw to increase fluid pressure, unscrew to decrease.
To flush the regulator for cleaning operation introduce the cylindricalside of the key into the regulator and screw at maximum to push thepin on the membrane support and open the regulator in order to have
optimum flushing fluid flow.

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Fig A

Fig B

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PARTS LIST
Rep.

Order Number

Description

Qty.

1

HGB-404-1

Adjusting key

1

2

HGB-28

Cover

1

3A

S-1309-H

For HGB-509-5-R38 or 609-x-R38, Screw M5 * 16

3B

S-1330-H

For HGB-510-R1, R2 & R4, or (CO), Screw M5 * 254

HGB-408-H

Adjusting screw assembly

1

5

HGB-7

Adjusting nut

1

6

HGB-403-H

Stem kit

1

HGB-13-H

Spring for diaphragm for HGB-509-5-R38 or HGB-609-5-R38.

HGB-42Spring for diaphragm for HGB-609-1.2-R38.

HGB-43

Spring for diaphragm for HGB-609-9-R38.

8A

S-24383

Connector M5 for Rilsan tube. 2.7 *4 mm

1

8B

SSP-6462

Elbow connector M5 for rilsan tube 2.7*4 mm

1

9

HGB-54

Cover for HGB-510

1

10

HGB-55-K

Air diaphragm HGB-510

1

11R1

HGB-67

Disc for HGB-510-R1 or R1CO

11R2

HGB-56

Disc for HGB-510-R2 or R2CO

11R4

HGB-63Disc for HGB-510-R4 or R4CO

12

HGB-68Intermediary washer for R2 & R4

12b

HGB-64

Intermediary washer for R4

13

HGB-57-1

Intermediary body

14m

HGB-422

Fluid diaphragm assy. for HGB-509, 609.

14R

HGB-424

Fluid diaphragm assy. for HGB-510-R1/R2/R4 or 1CO, 2CO, 4CO

7

15

6

1

1

1
1

Regulator body

1
1

HGB-426-CO

Kit of Fluid inlet & ball valve with spring (3/8’’BSP/NPS Male).

HGB-426

Kit of Fluid inlet & ball valve with spring (1/4’’BSP Female).

HGB-426-R38

Kit of Fluid inlet & ball valve with spring (3/8’’BSP/NPS Female).

17

S-28216

Gasket “D” shape1

18

HGB-62PTFE gasket

1/2

HGB-61

Fluid outlet connector for HGB-510-Rx, 1/4’’ Female

HGB-81

Fluid outlet connector for HGB-509-5-R38 & HGB-609-X-B38, 3/8’’ Male

HGB-82

Fluid outlet connector for HGB-609-xx-R38, 1/4’’ BSP Male20

HGB-49Fluid outlet insert connector for HGB-510-Rx-CO

1

21

HC-1000

Fluid outlet swivel connector for HGB-510-Rx-CO

1

HGB-60

Fluid inlet connector Female 1/4’’BSP for HGB-510-Rx

HGB-59Fluid inlet connector Male 3/8’’universal for HGB-510-Rx-CO

HGB-80

Fluid inlet connector Female 3/8’’BSP for HGB-509/609-R38

16

19

22

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1

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3. B
 low material back through the regulated line by introducing air
pressure into the line down stream from the regulator. With spraygun attached this can be done by loosening air cap ring on gun,holding a rag over air cap and pulling gun trigger. This forces air
in a reverse path through spray gun and air forces material backthrough regulated material line.
4. U
 nscrew the fluid inlet connector remove the spring and the ballvalve. Clean all the parts and the gasket inside the valve body. If thegasket is damaged replace it. Please follow the instruction describedon page 6. If the gasket is ok put thread locking compound (loctite222) on the connector thread and tighten to a maximum torque of
6.4Nm.
Periodically clean exterior of regulator with solvent soaked rag.

REPLACEMENT OF PARTS!

WARNING

Relieve the line pressure before servicing for pneumatic
model (HGB-510). For manual model HGB-509 & 609,
Relieve spring forces by unscrewing the adjusting screw
rep 4 at the maximum (FIG A).

OPERATION
Pneumatic adjustment regulator
For models HGB-510-R1, R2 or R4
The fluid pressure regulation is adjusted by remote air pressure
regulator, for that connect Rilsan tube on the top connector on cover.
To flush the regulator, connect air tube on the side connector (R1/R2/
R4) and set the air pressure to full open the valve regulator. It’s useful
to fit the air regulator close to the fluid regulator to obtain the accurate
regulation at a low fluid flow. If it’s not the case, you can obtain thisaccurate regulation in piercing the Rilsan tube with sewing needle nearof the connector to create a small air leakage.
To flush the fluid line with solvent, connect the flushing air commandto the right connector on the side of the regulator.

! CAUTION
DO NOT EXCEED THE FLUSHING AIR COMMAND MORE
THAN 1 BAR OVER THE SOLVENT PRESSURE.

TO REPLACE DIAPHRAGM
1. R
 emove the 6 hex. head cap screws.
2. T he diaphragm is sold complete with its washer and its fluid flow
plastic deflector. These parts could be not separated, if diaphragmor the deflector is damaged replace it.
3. I nstall the new diaphragm kit into the regulator body.
4. P ut the cover on the regulator and screw the 6 screws at 6.2 Nm.
5. 
For the pneumatic model HGB510, reassemble all the parts in
the right order and position. It’s recommended before to set theregulator that the two diaphragms work about 10 time so to be infull condition, this operation could be done in using the connector
Rep 8 and pressurize the flushing cavity at 4 bar.

TO SERVICE VALVE ASSEMBLY“Perlast D shape” seat and Ball valve.

NOTE

1. U
 nscrew the fluid inlet valve and connector rep 16 from the regulator
body.

To come back at the initial set up after cleaning operation,
purge the air line so to have no air pressure on
intermediary chamber. This intermediary chamber can beused as a safe area if the membrane brakes and fluid
leakage goes through the air line.

2. C lean and check the valve, if the parts are damaged, replace theparts in using the valve kit.

To know and differentiate what is your regulator model, an arrow ismarked above the cover which is either in direction of the flushing
air inlet connector for the R1 model or in direction of the 1/ 4 or
1/ 2 printed on the intermediary plate. Take care during the reassembling operation after maintenance to fit the cover in the rightplace corresponding to the model of regulator used.

3. F
 it the washer in the right position small dimension in front of the“D” gasket, Screw the valve body on the regulator body with asealing compound “loctite 270” on the third thread and tight at
maximum torque 12Nm, Do not exceed this torque, over torque will
damaged the regulator body.
4. W ait a few minutes for the loctite to dry and fit the ball valve andthe spring
5. C lean the thread on the fluid inlet connector, use a thread locking
compound like Loctite 222.
6. A
 pply a maximum torque 6.4Nm.

PREVENTIVE MAINTENANCE
Periodic cleaning of regulator with a solvent compatible with thematerial being used is recommended. To clean material from theregulated material line and the regulator, these steps should be
followed:
1. R
 elieve supply line pressure.
2. P ut the regulator in flushing position (See “Operation”). This holds
the valve off its seat.

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SERVICE CHECKSCONDITION

CAUSESREMEDES

Regulated pressure creep.

Improper seating of valve stem on seat.

Be sure that seat and ball valve are not damaged, worm
or dirty.

Diaphragm leaking.

Replace.

Restriction in main material line or at valve
seat inlet.

Clear l'obstruction

Diaphragm damaged.

Replace.

Loose cap screws.

Screw the 6 screws at a torque 8 mN.

Diaphragm damaged.

Replace.

Regulated pressure drop.

Fluid leakage from underbonnet.

ACCESSORIES

MA-25, GA-288

S-3008S-3007

S-3006

H-1580-H

Manometer 2.5b,6b or 10bar

Stainless steel adapter
1/4’’ BSP female / female

Stainless steel riser tube
1/4’’BSP – male/male

Tee in stainless steel
1/4’’ BSP – Female

Stainless steel
double male nipple,
1/4 bspt x 3/8 nps-bsp

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WARRANTY POLICYThis product is covered by Carlisle Fluid Technologies’ materials and workmanship limited warranty.
The use of any parts or accessories, from a source other than Carlisle Fluid Technologies,
will void all warranties. Failure to reasonably follow any maintenance guidance provided
may invalidate any warranty.
For specific warranty information please contact Carlisle Fluid Technologies.

For technical assistance or to locate an authorized distributor,
contact one of our international sales and customer support locations.
RegionIndustrial/Automotive

Automotive Refinishing

AmericasTel: 1-800-992-4657
Fax: 1-888-246-5732

Tel: 1-800-445-3988
Fax: 1-800-445-6643

Europe, Africa,
Middle East, India

Tel: +44 (0)1202 571 111
Fax: +44 (0)1202 573 488

China

Tel: +8621-3373 0108
Fax: +8621-3373 0308

Japan

Tel: +81 45 785 6421
Fax: +81 45 785 6517

Australia

Tel: +61 (0) 2 8525 7555
Fax: +61 (0) 2 8525 7575

For the latest information about our products, visit www.carlisleft.com

Carlisle Fluid Technologies is a global leader in innovative finishing technologies.
Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice.
BGK™, Binks®, DeVilbiss®, Hosco®, MS®, and Ransburg®
are all registered trademarks of Carlisle Fluid Technologies, LLC.
©2024 Carlisle Fluid Technologies, LLC.
All rights reserved.

16430 North Scottsdale Rd., Suite 450

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Scottsdale, AZ 85254 USA

SB-6-HGB-R5 (1/2024)