SERVICE MANUAL

EN
II2G

HGB-509 / HGB-510 / HGB-609 FLUID REGULATOR

DESCRIPTION

Manually adjusted or remote air pressure

controlled, these fluid regulators can
provide material at constant pressure
for one or two spray guns, using
stainless steel ball valve and spring,
“Perlast” valve seat. Especially design for
application with low paint viscosity and
needing accurate fluid flow regulation
(Low hysteresis level).

A Manual adjustment key

B Spring
C Diaphragm assembly
D Ball valve
E Fluid inlet
F Fluid outlet
G Pneumatic air command
H Flushing air command
J Piston & adjusting washer

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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

Notified body details and role: Element Materials Technology Rotterdam B.V. (2812)

Lodging of ATEX Technical file

This Declaration of Conformity / Incorporation is issued Carlisle Fluid Technologies Inc.

under the sole responsibility of the manufacturer: 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 in
accordance with any applicable local codes of practice.

Signed for and on behalf of

Carlisle Fluid Technologies: F. A. Sutter Executive President: Engineering and
Document Part No. Operations, Scottsdale, AZ, 85254. USA
4-3194R-4 EN 20/9/23

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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 Carlisle Fluid Technologies Inc.

under the sole responsibility of the manufacturer: 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 in
accordance with any applicable local codes of practice.

Signed for and on behalf of

Carlisle Fluid Technologies: F. A. Sutter Executive President: Engineering and
Document Part No. Operations, Scottsdale, AZ, 85254. USA
EN 20/9/23

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

! WARNING ! CAUTION NOTE

Hazards or unsafe practices which
Hazards or unsafe practices which
could result in severe personal Important installation, operation or
could result in minor personal injury,
injury, death or substantial property maintenance information.
product or property damage.
damage.

! WARNING
Read the following warnings before using this equipment.
READ THE MANUAL AUTOMATIC EQUIPMENT
Before operating finishing equipment, read and understand all Automatic equipment may start suddenly without warning.
safety, operation and maintenance information provided in the
operation manual.

WEAR SAFETY GLASSES

Failure to wear safety glasses with side shields could result in INSPECT THE EQUIPMENT DAILY
serious eye injury or blindness. 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 LOCK

OUT ALL POWER SOURCES DURING MAINTENANCE
NEVER MODIFY THE EQUIPMENT
Failure to De-energize, disconnect and lock out all power supplies
Do not modify the equipment unless the manufacturer provides
before performing equipment maintenance could cause serious
written approval.
injury or death.

OPERATOR TRAINING
All personnel must be trained before operating finishing
equipment. 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.

NOISE HAZARD
You may be injured by loud noise. Hearing protection may be
PROJECTILE HAZARD required when using this equipment.
You may be injured by venting liquids or gases that are released
under pressure, or flying debris.

HIGH PRESSURE CONSIDERATION

PINCH POINT HAZARD High pressure can cause serious injury. Relieve all pressure before
Moving parts can crush and cut. Pinch points are basically any servicing. Spray from the spray gun, hose leaks, or ruptured
areas where there are moving parts. components can inject fluid into your body and cause extremely
serious injury.

PACEMAKER WARNING STATIC CHARGE

You are in the presence of magnetic fields which may interfere Fluid may develop a static charge that must be dissipated through
with the operation of certain pacemakers. proper grounding of the equipment, objects to be sprayed and all
other 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.

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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SPECIFICATIONS
Thread Fluid flow
Inlet pressure Outlet pressure Manometer
Type Reg Order number maximum
Inlet Outlet min-max.bar max.bar bar
L/min

HGB-509-5-R38 2 – 12,5 5 13 No

HGB-609-1.2-B38 1 – 8 1,2 8,3 No

HGB-609-5-B38 2 – 12,5 5 13 No
Female Male
Manual Spring HGB-609-9-B38 3 – 15 9 13 No
3/8 3/8
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 – 15 9 13 0 – 10

HGB-510-R1 2 – 15 15 1,6 (Tip 1,1mm) No

Female Female
HGB-510-R2 1 – 15 7 1,3 (Tip 1,1mm) No
1/4 1/4
Pneumatic HGB-510-R4 1 – 15 4 0,8 (Tip 1,1mm) No
Adjustment HGB-510-R1-CO 2 – 15 15 1,6 (Tip 1,1mm) No
Male Female
HGB-510-R2-CO 1 – 15 7 1,3 (Tip 1,1mm) No
3/8 3/8
HGB-510-R4-CO 1 – 15 4 0,8 (Tip 1,1mm) No

ALL MODELS
Ambient Temperature Range: Fluid Temperature Range: Maximum Continuous Fluid Temperature:
0° – 50°C (32° – 122°F) 0° – 80°C (32° – 176°F) 60°C (140°F)

All the fluid passages are in stainless steel, membrane in PTFE, cover •C
 onnect the regulated fluid line, to supply one or two spray
in aluminum nickel treatment for manual model or anodized for remote gun, side port of the regulator at the ¼’’ BSP or 3/8’’ NPS/BSP
air control. universal (See on page 11 depend of version used).

The regulators HGB-609 are equipped with stainless steel tee and riser Swivel connector female is used for “CO” version on remote
tube and a manometer. The tightness of these connections ought to be control.
perfect so to protect the manometer.
•T
 he regulator must be earthed to dissipate any electrostatic
See drawings on « Accessories ». charge which may be created by fluid or air flows. This can be
achieved in using one of the screw ref 3A or 3B.
IMPORTANT: These regulators may be used with most
common coating and finishing materials. However, there are Electrical bond from the regulator to earth should be checked
not designed for use with highly corrosive materials which with an ohmmeter.
have such characteristics, it must be expected that frequent
and thorough cleaning will be required and/or the necessity A resistance of less than 106 Ohms is recommended.
for replacement of parts will be increased.
•A
 ssume that during the installation, the regulator will filled
completely the cavity under the diaphragm, this is to obtain
INSTALLATION the full accurate regulation specially in use at lower fluid flow
delivery.
•T
 he regulators must be fitted in horizontal position to remove

! CAUTION
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 be
done on the connectors so to remove any air leakage to protect It is recommended that at the initial installation the
the manometer. material supply line should not be flushed through the
regulator because pipe compound chips, scale, etc. may
•C
 onnect the fluid supply line, coming from pump or pressure lodge on the valve seat USE AN IN LINE FILTER.
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 cylindrical

side of the key into the regulator and screw at maximum to push the
pin on the membrane support and open the regulator in order to have
optimum flushing fluid flow. 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

6
3B S-1330-H For HGB-510-R1, R2 & R4, or (CO), Screw M5 * 25

4 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.

7 HGB-42 Spring for diaphragm for HGB-609-1.2-R38. 1

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 1

11R4 HGB-63 Disc for HGB-510-R4 or R4CO

12 HGB-68 Intermediary washer for R2 & R4

1
12b HGB-64 Intermediary washer for R4

13 HGB-57-1 Intermediary body 1

14m HGB-422 Fluid diaphragm assy. for HGB-509, 609.

1
14R HGB-424 Fluid diaphragm assy. for HGB-510-R1/R2/R4 or 1CO, 2CO, 4CO

15 Regulator body 1

HGB-426-CO Kit of Fluid inlet & ball valve with spring (3/8’’BSP/NPS Male).

16 HGB-426 Kit of Fluid inlet & ball valve with spring (1/4’’BSP Female). 1

HGB-426-R38 Kit of Fluid inlet & ball valve with spring (3/8’’BSP/NPS Female).

17 S-28216 Gasket “D” shape 1

18 HGB-62 PTFE gasket 1/2

HGB-61 Fluid outlet connector for HGB-510-Rx, 1/4’’ Female

19 HGB-81 Fluid outlet connector for HGB-509-5-R38 & HGB-609-X-B38, 3/8’’ Male 1

HGB-82 Fluid outlet connector for HGB-609-xx-R38, 1/4’’ BSP Male

20 HGB-49 Fluid 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

22 HGB-59 Fluid inlet connector Male 3/8’’universal for HGB-510-Rx-CO 1

HGB-80 Fluid inlet connector Female 3/8’’BSP for HGB-509/609-R38

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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 spray
gun 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 back
through regulated material line.
4. U
 nscrew the fluid inlet connector remove the spring and the ball
valve. Clean all the parts and the gasket inside the valve body. If the
gasket is damaged replace it. Please follow the instruction described
on page 6. If the gasket is ok put thread locking compound (loctite
222) 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
OPERATION model (HGB-510). For manual model HGB-509 & 609,
Relieve spring forces by unscrewing the adjusting screw
Pneumatic adjustment regulator
rep 4 at the maximum (FIG A).
For models HGB-510-R1, R2 or R4
TO REPLACE DIAPHRAGM
The fluid pressure regulation is adjusted by remote air pressure
regulator, for that connect Rilsan tube on the top connector on cover. 1. R
 emove the 6 hex. head cap screws.
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 2. T
 he diaphragm is sold complete with its washer and its fluid flow
to fit the air regulator close to the fluid regulator to obtain the accurate plastic deflector. These parts could be not separated, if diaphragm
regulation at a low fluid flow. If it’s not the case, you can obtain this or the deflector is damaged replace it.
accurate regulation in piercing the Rilsan tube with sewing needle near 3. I nstall the new diaphragm kit into the regulator body.
of the connector to create a small air leakage.
4. P
 ut the cover on the regulator and screw the 6 screws at 6.2 Nm.
To flush the fluid line with solvent, connect the flushing air command 5. F
or the pneumatic model HGB510, reassemble all the parts in
to the right connector on the side of the regulator. the right order and position. It’s recommended before to set the
regulator that the two diaphragms work about 10 time so to be in

! CAUTION
full condition, this operation could be done in using the connector
Rep 8 and pressurize the flushing cavity at 4 bar.

DO NOT EXCEED THE FLUSHING AIR COMMAND MORE

THAN 1 BAR OVER THE SOLVENT PRESSURE.
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 2. C
 lean and check the valve, if the parts are damaged, replace the
intermediary chamber. This intermediary chamber can be parts in using the valve kit.
used as a safe area if the membrane brakes and fluid
3. F
 it the washer in the right position small dimension in front of the
leakage goes through the air line.
“D” gasket, Screw the valve body on the regulator body with a
sealing compound “loctite 270” on the third thread and tight at
To know and differentiate what is your regulator model, an arrow is maximum torque 12Nm, Do not exceed this torque, over torque will
marked above the cover which is either in direction of the flushing damaged the regulator body.
air inlet connector for the R1 model or in direction of the 1/ 4 or 4. W
 ait a few minutes for the loctite to dry and fit the ball valve and
1/ 2 printed on the intermediary plate. Take care during the re the spring
assembling operation after maintenance to fit the cover in the right
place corresponding to the model of regulator used. 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 the
material being used is recommended. To clean material from the
regulated 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 CHECKS

CONDITION CAUSES REMEDES

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.
Regulated pressure drop. Restriction in main material line or at valve Clear l'obstruction
seat inlet.
Diaphragm damaged. Replace.
Fluid leakage from under Loose cap screws. Screw the 6 screws at a torque 8 mN.
bonnet.
Diaphragm damaged. Replace.

ACCESSORIES

MA-25, GA-288 S-3008 S-3007 S-3006 H-1580-H

Manometer 2.5b, Stainless steel adapter Stainless steel riser tube Tee in stainless steel Stainless steel
6b or 10bar 1/4’’ BSP female / female 1/4’’BSP – male/male 1/4’’ BSP – Female double male nipple,
1/4 bspt x 3/8 nps-bsp

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WARRANTY POLICY

This 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.

Region Industrial/Automotive Automotive Refinishing

Tel: 1-800-992-4657 Tel: 1-800-445-3988

Americas
Fax: 1-888-246-5732 Fax: 1-800-445-6643

Europe, Africa, Tel: +44 (0)1202 571 111

Middle East, India Fax: +44 (0)1202 573 488

Tel: +8621-3373 0108

China
Fax: +8621-3373 0308

Tel: +81 45 785 6421

Japan
Fax: +81 45 785 6517

Tel: +61 (0) 2 8525 7555

Australia
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 Scottsdale, AZ 85254 USA

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