Graco 308224H President Hydra Cat Proportioning Pumps Users Manual Pumps, Instructions Parts, English
2015-04-02
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Instructions – Parts List PRESIDENT HYDRA-CATr FIXED RATIO Proportioning Pumps 308224H EN 3000 psi (21 MPa, 210 bar) Maximum Working Pressure Two or Three Displacement Pump Models in Various Mix Ratios, Pressure Ratios, and Flow Volume Available as Bare Pumps, or as Wall-Mounted* or Free-Standing Models *Includes Mixing Manifolds, Automatic Pressure Relief Valves, Check Valves, Pressure Gauges, and Regulators. For models that are see pages 6 and 7. certified and approved Read warnings and instructions. See page 2 for Table of Contents and page 6 for List of Models. 02884A Table of Contents Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation – Optional Fluid Heaters . . . . . . . . . . . . . . 13 Installation – Optional Solvent Pump . . . . . . . . . . . . . 15 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Shutdown and Care of the System . . . . . . . . . . . . . . . 21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Service – Displacement Pump . . . . . . . . . . . . . . . . . . 24 Parts – Bare, Two Pumps . . . . . . . . . . . . . . . . . . . . . . Parts – Bare, Three Pumps . . . . . . . . . . . . . . . . . . . . . Parts – Wall Mount, Two Pumps . . . . . . . . . . . . . . . . . Parts – Wall Mount, Three Pumps . . . . . . . . . . . . . . . Parts – Stand Mount, Two Pumps . . . . . . . . . . . . . . . Parts – Stand Mount, Three Pumps . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Hole Layout for Air Motor . . . . . . . . . . . . . . Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 28 30 32 34 36 38 42 42 43 44 44 WARNING Plural Component Materials Hazard Graco, Inc. does not manufacture or supply any of the reactive chemical materials that may be used in this equipment and is not responsible for their effects. Because of the vast number of chemicals that could be used and their varying chemical reactions, before using this equipment, the buyer and the user should determine all facts relating to the materials used, including any of the potential hazards involved. Particular inquiry and investigation should be made into the potential dangers relating to toxic fumes, fires, explosions, reaction times, and exposure of human beings to the individual components or their resultant mixtures. Graco assumes no responsibility for loss, damage, expense, or claims for bodily injury or property damage, direct or consequential, arising from the use of such chemical components. 2 308224 Symbols Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions. WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury. D This equipment is for professional use only. D Read all instruction manuals, tags, and labels before operating the equipment. D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor. D Do not alter or modify this equipment. Use genuine Graco parts and accessories. D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not exceed the maximum working pressure stated on the equipment or in the Technical Data for your equipment. Do not exceed the maximum working pressure of the lowest rated component in your system. D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings. D Handle hoses carefully. Do not pull on hoses to move equipment. D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 66_C (150_F) or below –40_C (–40_F). D Wear hearing protection when operating this equipment. D Do not move or lift pressurized equipment. D Comply with all applicable local, state, and national fire, electrical, and safety regulations. 308224 3 WARNING INJECTION HAZARD Spray from the valve, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury. D Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious injury. Get immediate medical attention. D Do not point the valve at anyone or at any part of the body. D Do not put your hand or fingers over the valve tip. D Do not stop or deflect leaks with your hand, body, glove or rag. D Do not “blow back” fluid; this is not an air spray system. D Always have the tip guard and the trigger guard on the valve when spraying. D Be sure the valve trigger safety operates before dispensing. D Lock the valve trigger safety when you stop dispensing. D Follow the Pressure Relief Procedure on page 21 if the spray tip clogs and before cleaning, checking or servicing the equipment. D Tighten all fluid connections before operating the equipment. D Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses cannot be repaired; replace the entire hose. MOVING PARTS HAZARD Moving parts, such as the air motor piston, can pinch or amputate your fingers. D Keep clear of all moving parts when starting or operating the pump. D Keep hands and fingers away from the piston during operation and whenever the pump is charged with air. D Before checking or servicing the equipment, follow the Pressure Relief Procedure on page 21 to prevent the equipment from starting unexpectedly. 4 308224 WARNING FIRE AND EXPLOSION HAZARD Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury. D Ground the equipment and the object being sprayed. Refer to Ground the Pumps on page 10. D If there is any static sparking or you feel an electric shock while using this equipment, stop spraying immediately. Do not use the equipment until you identify and correct the problem. D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed. D Keep the spray area free of debris, including solvent, rags, and gasoline. D Before operating this equipment, electrically disconnect all equipment in the spray area. D Before operating this equipment, extinguish all open flames or pilot lights in the spray area. D Do not smoke in the spray area. D Do not turn on or off any light switch in the spray area while spraying or while operating if fumes are present. D Do not operate a gasoline engine in the spray area. TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed. D Know the specific hazards of the fluid you are using. D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines. D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer. 308224 5 List of Models Pressure and Ratio Ratings for President Pumps WARNING To reduce the risk of over pressurizing a component, which can result in an explosion and serious injury, never operate the system at a working pressure higher than the lowest rated component in the system. All fluid side components such as dispensing valves, regulators, and hoses must have a working pressure equal to or greater than the pressure given in Column B for each pump model. Column A gives the maximum fluid pressure developed at 100 psi (0.7 MPa, 7 bar) of incoming air pressure. Column B gives the minimum working pressure required for all system components, based on the automatic relief valve settings. Components included by Graco with the models listed meet or exceed this requirement. Models with Two Displacement Pumps Model No. B Minimum Component Working Pressure Normal Pressure Ratio (Fluid to Air) Nominal Flow Volume @ 40 cpm Mix Ratio Bare Wall Stand psi bar psi bar 1:1 231643** 231593** 231618** 1280 89 1800 124 12.80 1.5 5.7 1:1 231644 1601 112 1800 124 16.01 1.2 4.5 1:1 231645** 1921 135 2300 159 19.21 1.0 3.8 1:1 231646** 2561 179 2900 200 25.61 0.75 2.8 ** CE approved and 6 A Maximum Pump Fluid Pressure at 100 psi (7 bar) Air 308224 231595** certified. gpm lpm List of Models Models with Three Displacement Pumps Model No. Mix Ratio A B Maximum Pump Fluid Pressure at 100 psi (7 bar) Air Minimum Component Working Pressure Bare Wall Stand psi bar psi bar 2:1 231657** 231607** 231632** 1280 88 1800 124 2:1 231658** 1707 118 1800 4:1 231663** 1024 71 1150 **CE approved and 231613** 231638** Normal Pressure Ratio (Fluid to Air) Nominal Flow Volume @ 40 cpm gpm lpm 12.80 1.50 88 124 17.07 1.12 118 79 10.24 1.87 71 certified 308224 7 Typical Installation NOTE: When pressure feeding the proportioning pump, mount fluid pressure gauges (J) at the proportioning pump inlets to monitor proper adjustment of the feed pump pressures. Never exceed 25% of the Hydra-Cat pump outbound fluid pressure on the feed supply. About the Typical Installations These pumps are designed to be part of a Hydra-Cat dispensing system that will proportion, mix, and dispense two-component fluids. The typical installations shown below and on page 9 are only guidelines to setting up a complete proportioning system. For clarity, various components are shown in the correct order but may not be shown in exactly the position of the installed system. For assistance in designing your system, contact your Graco distributor. Light Viscosity System Two Displacement Pumps, 5:1 Ratio Feed Pumps KEY A B C D E F G Bleed-type master air valve Air filter Air lubricator Pump runaway valve Pump air regulator Feed pump Ground wire B H J K L Proportioning pump Fluid pressure gauge Check valve Automatic pressure relief valve M Fluid filter N Mixer manifold P Q R S T U V Fluid drain valve Fluid shutoff valve Static mixer Dispense valve Fluid regulator Solvent pump Fluid strainer 1 See note above 2 Connect to drain bottle. See Fig. 5, page 11 * Included with wall or stand models A F H G J* K* L* M S N* C P* R D HARD E* E RES A* A 2 HARD RESIN Q T U M RES HARDENER Q* K J* 1 V* Q* 02885 Fig. 1 8 308224 Typical Installation NOTE: When pressure feeding the proportioning pump, mount fluid pressure gauges (J) at the proportioning pump inlets to monitor proper adjustment of the feed pump pressures. Never exceed 25% of the Hydra-Cat pump outbound fluid pressure on the feed supply. About the Typical Installations These pumps are designed to be part of a Hydra-Cat dispensing system that will proportion, mix, and dispense two-component fluids. The typical installations shown below and on page 8 are only guidelines to setting up a complete proportioning system. For clarity, various components are shown in the correct order but may not be shown in exactly the position of the installed system. For assistance in designing your system, contact your Graco distributor. Heavy Viscosity Heated System Three Displacement Pumps, 10:1 Ratio Feed Pumps KEY A B C D E F G H Bleed-type master air valve Air filter Air lubricator Pump runaway valve Pump air regulator Feed pump Ground wire Proportioning pump B J K L Fluid pressure gauge Check valve Automatic pressure relief valve M Fluid filter N Mixer manifold P Fluid drain valve Q Fluid shutoff valve R S T U V W X Static mixer Dispense valve Fluid regulator Solvent pump Fluid strainer Fluid heater Supply manifold 1 See note above 2 Connect to drain bottle. See Fig. 5, page 11 * Included with wall or stand models A F G H J* K* L* W M S N* C P* R D 2 E E* Q A* Q* K A 2 X J* T U M 1 V* Q* 02886 Fig. 2 308224 9 Installation Bare Pumps Bare pumps are available for those installations which require a highly customized system. For a safe and efficient system, Graco recommends that the air and fluid components supplied with the Wall Mount and Cart Mount models also be used in customized systems. Refer to the Parts Drawings on pages 26–37 for part numbers. In addition, the accessories shown in the Typical Installation drawings and discussed in the following pages of this manual should be used. For a wall mount, be sure the bracket and wall are strong enough to support the pump, accessories, plumbing and stress caused by pump operation. Locate the bracket about 5 ft (1.5 m) above the floor. Ground the Pumps WARNING FIRE AND EXPLOSION HAZARD Before operating the pump, ground the system as explained below. Also read the section FIRE AND EXPLOSION HAZARD on page 5. Be sure all accessories are sized properly for the air and fluid requirements of your system. Read all instructions in the Installation section for further details. NOTES: 1. Models with three displacement pumps always use the two outer displacement pumps to supply the resin and the middle displacement pump to supply the hardener. 1. These pumps always use the two outer displacement pumps to supply the resin and the middle displacement pump to supply the hardener. 1. Loosen the grounding lug locknut (BB) and washer (AA). 2. Insert one end of a 14 ga (1.5 mm@) minimum ground wire (G) into the slot in lug (CC) and tighten the locknut securely. See Fig. 3. 3. Connect the other end of the ground wire to a true earth ground. Order part number 237569 Grounding Clamp and wire. 2. Label all pumps, hoses, fluid regulators, etc. to indicate whether they are for the resin side or hardener side of the system. G Mounting the Pump Mount the pump to suit your installation. The bare pump can be mounted on a wall bracket or on a cart. See the Mounting Hole Layout on page 42. The President pump and accessories weigh approximately 65 lb (30 kg). The pump stand and accessories weigh approximately 55 lb (25 kg). 10 308224 AA Fig. 3 BB CC Installation Air Control Accessories Automatic Pressure Relief Valves Install the accessories in the order shown in Fig. 4. Mount only the air regulator (E) and a master air valve (A) at the pump. Mount all other accessories on separate wall brackets to reduce stress on the pump inlet. Note that one air filter (B) can serve multiple pumps by using an air manifold downstream from the air filter. WARNING Bleed-type master air valves (A) are required in the system in the positions shown in the Typical Installation drawings. These valves are used during system pressure relief to relieve air trapped in the air line. Trapped air can cause the pump to cycle unexpectedly and result in serious injury from moving parts, fluid injection, or fluid splashing. 1. Install a bleed-type master air valve (A) in the pump air inlet. 2. Install an air regulator and gauge (E) to control pump outlet pressure. 3. Install a pump runaway valve (D) for each feed pump to automatically shut off the air to the pump if the pump accelerates beyond the pre-adjusted setting. A pump which runs too fast can be seriously damaged. WARNING To reduce the risk of component rupture, which could cause serious injury and property damage, the appropriate automatic pressure relief valve is required for each fluid on a plural component pump. These valves automatically relieve fluid pressure if the pump output pressure exceeds the valve’s preset pressure. Over pressurization may occur if there is a fluid line clog upstream from the valve or if any other condition exists that causes one of the pumps to cavitate and direct all fluid pressure to the other pump(s). See the List of Models on page 6 to determine the preset pressure in your system. Two drainage bottle kits (38) are included with wall models (unassembled) and stand mount models (assembled) to catch the drainage if the automatic pressure relief valves open. For the wall mount models, assemble the kit as shown in Fig. 5 and mount it securely to a wall or bracket. Use the tie wrap, supplied, to hold the hoses out of the way, if necessary. WARNING 4. Install an air line lubricator (C) for automatic air motor lubrication. 5. Install an air filter (B) to remove harmful dirt and moisture from the compressed air supply. B A Fluid emitted from the automatic pressure drain valves may be at pressures over 3000 psi (21 MPa, 210 bar). Make sure the drain bottles are securely fastened to the frame or wall so that they can handle a sudden spurt of pressurized fluid. 18 A E 38a 38b G 38c C Fig. 4 38f 38g 38h D 02887 02888A Fig. 5 308224 11 Installation DD NOTE: If you mount the pump on a wall, turn the displacement pump inlet assemblies (CC) to face forward, rather than backwards as shown in Fig. 6. EE 37B Connect Fluid Supply Hoses RES For Two Displacement Pump Models HARD 1. Connect the resin supply hose (EE) to the 3/4 npt swivel inlet (37B) for the resin displacement pump. See Fig. 6. 37A 2. Connect the hardener supply hose (DD) to the 3/4 npt swivel inlet (37A) for the hardener displacement pump. See Fig. 6. CC 02889 Fig. 6 For Three Displacement Pump Models 37B RES 2. Connect the hardener supply hose (DD) to the 3/4 npt swivel inlet (37) for the center (hardener) displacement pump. See Fig. 7. HARD RES 1. Connect the resin supply hose (EE) to the 3/4 npt swivel inlet (37B) for the resin displacement pumps. See Fig. 7. EE Additional System Components Install and connect the feed pumps, solvent pump, heaters, etc. Refer to the Typical Installation (Fig. 1–2) and Accessories on pages 38–39 for parts information. Use a dry air kit or a nitrogen regulator kit to protect the fluid in the supply containers from moisture that can crystallize the fluid and cause the ball checks to malfunction. See Accessories on page 39. 12 308224 DD 37A Fig. 7 02890 Installation – Optional Fluid Heaters All Models NOTE: For systems requiring one heater for each fluid, see page 38 to order the heaters and required plumbing (items 201 to 205). 201a 201b 201 202 204 OUT 1. Mount a heater to each side of the mounting bracket using the three screws (201a) and lockwashers (201b) supplied with each heater. See Fig. 8. 2. Connect a swivel union (202) to the outlet of each heater. See Fig. 8. IN 3. Connect a swivel union (203) to the inlet of each heater. See Fig. 8. For Two Displacement Pump Models 203 1. Disconnect the existing hardener hose (10B) from the inlet of the mixer manifold (23). See Fig. 8. Connect the free end of the hose to the swivel (203) at the hardener heater inlet. See Fig. 9. 10 02891A Fig. 8 2. Install a new fluid hose (204B) between the hardener heater outlet (202B) and the hardener mixer manifold. See Fig. 8–9. WARNING To reduce the risk of serious injury, follow the Pressure Relief Procedure on page 21 before installing the heaters. 3. Repeat Steps 1 and 2 for the resin pump (the “A” side). 23 (N) HARD RES 204B 204A 202B 202A RE S HAR D OUT OUT RES 203A HARD RES 10A IN HARD IN 203B 10B 02893 Fig. 9 308224 13 Installation – Optional Fluid Heaters 23 (N) 204B 205A FA RES RES HARD 17A 202A FB HARD 17B RES HEATE R OUT RES HARD RES IN 202B HARD HEATE R OUT IN 203A 203B 02894 Fig. 10 For Three Displacement Pump Models 16A 17A NOTE: You must provide two hoses (FA, FB in Fig.10) and fittings to run from the heater outlets to the mixer manifold inlets. 17B 16B NOTE: To accommodate two resin fluid hoses, the mixer manifold (23) must be disconnected from the bracket and mounted remotely. 3. Install another hardener fluid hose (FB) between the heater outlet elbow (202B) and the hardener side of the mixer manifold (23). See Fig. 10. 4. Repeat Steps 1 to 3 for the resin side of the system (the “A” side). 14 308224 HARD 2. Connect a new hardener fluid hose (204B) between the union (17B) and the swivel (203B) at the heater inlet. See Fig. 10. RES 1. Loosen the swivel of the unions (17A, 17B) to remove the elbow (16A, 16B) on each side of the mixer manifold (23). Turn the unions (17A, 17B) so the outlet faces up. See Fig. 10 and 11. (N) 23 02892A Fig. 11 Installation – Optional Solvent Pump NOTE: The optional solvent pump is not offered as a kit; order parts as needed. The optional parts shown here are listed on page 39. These instructions assume that the pump is being mounted to the back of the stand offered in this manual. The Typical Installations on pages 8–9 show alternate installations. Adjust your installation according to your specific needs. 4. Couple the hose (303) and couplings (302). Connect the hose (303) to the adapter (301). 5. Install the other adapter (301), needle valve (304) and adapter (305) to the pump inlet. 6. Connect the adapter (307), elbow (308) and fluid hose (309) to the pump outlet. 1. Mount the solvent pump bracket (301) on the back of the stand. 2. Mount the pump (306) to the bracket using the hardware supplied with the pump. 7. Install a fluid shutoff valve (311) at the mixer manifold swivel union (15). This valve is used to prevent resin or hardener from backing up into the solvent system, and to isolate the solvent system for service. Connect the solvent inlet hose (309). 3. Use the existing proportioning pump air regulator (5) to supply air to the solvent pump. Remove the plug from the back of the swivel union (3) and install the adapter (301). Rotate the regulator gauge elbow (4) so the gauge is facing the operator. 8. Connect the suction hose assembly (312) to the pump intake. 309 305 A 306 A 311 15 303 302 301 304 307 308 B 3 309 4 316 315 310 301 302, 303 314 313 B 5 312 02902B Fig. 12 308224 15 Flushing When to Flush the System How to Operate the Mixer Manifold D Flush the system before its first use to remove the light oil which was left in after factory testing. To open or close the mixer manifold (N) fluid valves (LL) push the handle (KK) down to open and up to close. See Fig. 13. D Flush the manifold mixer (N), using the solvent pump, as frequently during the day as necessary to avoid exceeding the pot life limit of the material being pumped. KK 1 UP – closed 2 DOWN – open LL LL 1 D Flush frequently enough during regular operation to prevent clogged passages due to material being overheated or dried out in any part of the system. Clogged passages in the heater can be very difficult to clean and can reduce heating efficiency, flow rate and pressure. 2 N2 RES HARD N1 N D Flush the entire system when the system is shut down for a long period of time. Keep in mind that some moisture may get into the lines, which could contaminate the hardener, so flush again before restarting the system. P1 P2 02895 Fig. 13 KEY A Bleed-type master air valve E A1 A2 A3 A4 A5 Hardener feed pump Resin feed pump Proportioning pump Solvent pump Feed & Proportioning pump master air valve A6 Solvent pump master air valve Pump air regulator E1 E2 E3 E4 J H N Q Hardener feed pump Resin feed pump Proportioning pump Solvent pump Proportioning pump Mixer manifold Fluid shutoff valve Q1 Proportioning pump intake Q2 Mixer manifold solvent inlet Fluid pressure gauge J1 Proportioning pump intake J2 Proportioning pump outlet A6 A5 E3 A3 Q2 H N HARD HARD A2 A1 E1 E2 RES RES Fig. 14 16 308224 J2 J1 E4 Q1 A4 02896 Flushing How to Flush the System WARNING If your system is equipped with heaters, always shut off the main power to the heaters before flushing. Circulate the fluid through the system for at least 10 minutes to cool the fluid and the heater. This reduces the risk of serious injury from burns. NOTE: For the first time flushing, we recommend using mineral spirits solvent (also called white spirit) to flush out the oil. Then flush again using a solvent that is compatible with the fluid you will be dispensing. However, be sure the mineral spirits solvent is compatible with the material you will be pumping. If it is not, check with your fluid supplier to determine an appropriate solvent for flushing out the light oil. To flush the solvent valves . . . 11. Open the hardener solvent flush valve (N1) on the mixer manifold (N). See Fig. 13. a. Be sure the solvent pump air regulator (E4) is at minimum pressure. See Fig. 14. b. Open the solvent pump main master air valve (A6) and then open the pump air valve (A4). See Fig. 14. c. Release the dispensing valve safety latch. Hold the dispensing valve firmly against a grounded pail and trigger it while slowly opening the solvent pump air regulator (E4). Operate the pump slowly until the dispense line is flushed. Release the dispensing valve trigger and engage its safety latch. Close the hardener solvent flush valve (N1). For flushing only . . . d. Open the resin solvent flush valve (N2) and repeat Step c. See Fig. 13. NOTE: The proportioning pump is not operated during flushing. The solvent from the feed pumps will flush the proportioning pump displacement pumps. e. Close the solvent line shutoff valve (Q2). See Fig. 14. 1. Place each feed pump intake into a separate 5 gallon grounded pail, containing about 3 gallons (12 liters) of solvent. To flush or prime . . . 2. Be sure both of the fluid shutoff valves (Q1) are open. See Fig. 14. 3. Place a container under the drain valves (P1,P2) of the mixer manifold (N). See Fig. 13. 4. Be sure the feed pump air regulators (E1,E2) are at minimum pressure. See Fig. 14. 5. Open the main master air valve (A5). See Fig. 14. 6. Open the hardener pump master air valve (A1). See Fig. 14. CAUTION Always close the solvent line fluid shutoff valve (Q2) after the flushing procedure has been completed. This will prevent the other fluids from leaking into the flushing line. If this is a first time flush . . . 12. Repeat the flushing procedure using a solvent compatible with the fluid you are going to dispense. When you are done flushing . . . 13. Remove the solvent supply from the feed pumps. Operate the pumps slowly to push all the solvent out of the lines, then stop the pumps. If you are not going to use the system . . . 7. Slowly increase the air regulator (E1) setting until the pump is running slowly. 8. Open the hardener side drain valve (P1). Open the mixer manifold handle (KK). See Fig. 13. 9. When the hardener lines are flushed, close the mixer manifold handle and close the drain valve (P1). Close the air valve (A1). See Fig. 14. 10. Repeat Steps 6 to 9 for the resin feed pump. The resin sides uses these parts: regulator (E2), air valve (A2), drain valve (P2). 14. Close all air regulators, master air valves and fluid shutoff valves. Follow the Pressure Relief Procedure on page 21. WARNING Always close the air valve (A4) to the solvent pump before opening the fluid drain valves (P2) to relieve system pressure. This will reduce the risk of excessive pressure buildup in the opposite component hose and fittings. 308224 17 Operation Check the Drainage Bottles and Hoses WARNING WARNING Handling Plural Component Materials Be extremely cautious when handling plural component materials and solvents used with them. Some are extremely toxic. See the WARNING on the front cover. Read and follow the coating and solvent manufacturer’s safety precautions and warnings, including information regarding protective clothing, eyewear, and respirators. When spraying reactive fluids, wear the proper protective clothing, eye protection, gloves, and clean air breathing apparatus as prescribed by the fluid manufacturers recommendations, O.S.H.A. regulations and as approved by N.O.I.S.H. for the chemicals being used. Observe the Pot Life Limit To reduce the risk of serious injury and property damage, regularly check and clean the drain hose and bottle for the automatic pressure relief valve. If material is allowed to dry in and clog the drain hose, the automatic pressure relief valve may not fully release the fluid pressure if it opens or may cause the drain hose to burst. Check the drain hose and bottle (38) at the start of each shift, and whenever there is an imbalance of material, to see if the automatic pressure drain valve has released material into the bottles. Clean the hose and bottle as needed. Regularly check the drain hose for cuts, leaks, or bulges and replace damaged components before using the system. See Fig. 16. Flush the mixed fluid out of the mixer, dispensing lines and equipment before it hardens. Flush the complete system when necessary to prevent the fluids from hardening in the equipment and hoses. Check the fluid manufacturer’s instructions for fluid shelf life, and flush the entire system before this time is reached. Flush the system with a compatible solvent as explained on page 17. Fill the Throat Packing Nuts Verify compatibility of the pump oil with the fluids being used in the pumps. During operation very small amounts of this fluid are dragged past the seals and into the pump. 308224 Monitor the Material Supply CAUTION Establish a rigid system for monitoring the material supply to prevent the pumps from running dry. A sudden lack of material in one pump may cause many system problems, including air entrapment, spitting of the fluids, fluid “crossovers”, pump damage, downtime, and added system stresses. Never allow the feed pump or solvent pump containers to run dry. A dry container allows air to be pumped into the system and causes incorrect proportioning. A dry pump will quickly accelerate to a high speed, and may damage itself and the other displacement pump because it causes a pressure rise in the other pump. If a supply container becomes dry, stop the pump immediately, refill the container, and prime the system. Be sure to eliminate all the air from the system. JJ 18 02948A Fig. 16 Keep each displacement pump throat packing nut (JJ) filled with Graco ISO Pump Oil to help prevent fluid from drying on the displacement rod and damaging the pump packings. See Fig. 15. Fig. 15 38 02897 NOTE: The pump runaway valve mentioned on page 11 of the Installation section shuts off the pump if the pump speed accelerates quickly. Operation 6. Open the mixer manifold (N) and trigger the dispense valve (S). Startup WARNING 7. Set the air pressure to the feed pumps at 88 psi (0.6 MPa, 6 bar) or 25% of proportional pressure at the fluid outlets, whichever is less. Use the gauges (J1) to monitor this pressure. Higher pressures may prevent the proportioning pump inlet ball checks from setting properly. To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or the skin, and property damage, never exceed the maximum air and fluid working pressure of the lowest rated component in your system. See Equipment Misuse Hazard, System Pressure, on page 3. 8. Set the air pressure to the proportioning pump (H) to obtain the required fluid pressure. Refer to the proportioning pump chart on page 6 for the fluid to air pressure. 1. Install full containers of resin and hardener at the feed pumps. 9. While triggering the dispensing valve, check the fluid outlet pressure gauges (J2) and make note of the pressures indicated. Check the gauges frequently during operation. These notes will help to analyze any problems that may occur since a change in displacement pump performance will be indicated by a change in pressure gauge readings. 2. To prime the system, follow Steps 2 to 11 of the Flushing procedure on page 17. 3. Turn on the heaters, if used, and allow them to warm up for 10 minutes. 4. Open the feed pump air valves (A1,A2). Adjust the air regulators (E1,E2) just enough to start the pumps operating slowly. NOTE: A pressure drop does occur during pump stroke changeover. 5. Open the proportioning pump air valve (A3) and slowly open the regulator (E3) to start the proportioning pump. NOTE: Flush the mixer manifold frequently during the day’s operation. Follow Step 11 on page 17. KEY A Bleed-type master air valve E A1 Hardener feed pump A2 Resin feed pump A3 Proportioning pump Pump air regulator E1 Hardener feed pump E2 Resin feed pump E3 Proportioning pump E3 A3 H N S Proportioning pump Mixer manifold Dispense valve H S N A2 A1 E1 Fig. 17 E2 02886 308224 19 Operation NOTE: Since this is a fixed ratio system, you typically do not have to check the mix ratio. 10. While observing the pump outlet gauges (J2), adjust the resin and hardener drain valves (P1,P2) until the gauges show your normal operating pressure. If the mixed fluid does not cure or harden properly, check the ratio of resin to hardener. NOTE: The pressure must be within 20% of the original spraying pressure to get a usable test. Checking the Mix Ratio 1. Flush the mixer manifold; see Step 11 on page 17. 2. Follow the Pressure Relief Procedure on page . 3. Open the mixer manifold (N). 4. Set the operating pressure for the pumps. See Steps 7 and 8 on page 19. 5. Release the dispensing valve trigger and engage the safety latch. 6. Close the mixer manifold (N). 7. Open the hardener side drain valve (P2) about three turns. Open the resin side drain valve (P1) about 1 turn. This prevents the pressure from building up on the hardener pump, which would cause the automatic pressure relief valve to open. 11. Close the mixer manifold. Put a separate sampling container under each drain valve. 12. Open the mixer manifold to draw a sufficient sample. 13. As you close the mixer manifold, check the pump outlet gauges (J2) again to make sure they are at your normal operating pressure. NOTE: If the fluid pressure is not within 20% of the normal operating pressure, flush the mixer manifold again and take another sample. If the sample ratio is incorrect, refer to the Troubleshooting chart on page 22. If the ratio is correct, the problem is with one of the other system components. 8. Place a grounded metal pail under the drain valves. 14. Compare the volume of the sampling containers. If the ratio is not correct, refer to the Troubleshooting chart on page 22. If the ratio is correct the problem is one of the other components. 9. Open the mixer manifold. 15. Close the drain valves (P1,P2). J2 KK N P1 P2 Fig. 18 20 308224 J2 02898A Shutdown and Care of the System Pressure Relief Procedure WARNING INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you: D D D D are instructed to relieve the pressure, stop spraying, check or service any of the system equipment, or install or clean the spray tips. 1. Engage the dispensing valve safety latch. 2. Shut off the feed pump and proportioning pump air regulators and bleed-type master air valves. 3. If the system has heaters, circulate the fluid for at least 10 minutes to cool the heated fluid and heater. If you suspect that the nozzle or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen the nozzle or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the nozzle or hose. System Shutdown To shut the system down, shut off the air to all pumps, trigger the dispensing valve into a grounded metal waste container. Close the mixer manifold valves. Flush all the mixed fluid out of the mixer manifold, hoses and dispensing equipment. See page 17. Then follow the Pressure Relief Procedure. Cleaning the Pump Inlet Strainer If the fluid pressure from the feed pump to the proportioning pump cannot be maintained on the proportioning pump intake gauge (J), check and clean the strainer (V). Care of the Pump Throat Packing Nuts Keep the throat packing nuts filled with appropriate lubricant and check the tightness of the packing nut weekly. See Fig. 19. The packing nut should be tight enough to prevent leakage; no tighter. Too tight an adjustment causes the packings to bind or wear prematurely and leak. Always follow the Pressure Relief Procedure before adjusting the packing nut. 4. Disengage the dispensing valve safety latch. 5. Hold a metal part of the dispensing valve firmly to the side of a grounded metal pail, and trigger the dispensing valve to relieve pressure. 6. Engage the safety latch. 7. Open the mixer manifold drain valves (required in your system), having a container ready to catch the drainage. Close the valves immediately. 8. Use the solvent pump to flush the mixer manifold valves. JJ Fig. 19 308224 21 Troubleshooting WARNING WARNING To reduce the risk of serious bodily injury, always follow the Pressure Relief Procedure on page 21 whenever you shut off the pump, when checking or servicing any part of the dispensing system, when installing, cleaning or changing fluid tips, and whenever you stop dispensing. This chart uses the proportioner gauges to determine pump malfunctions. Faulty manifold check valves can mask pump cylinder problems. Always keep these valves operating properly. Never operate the pump with the air motor plate removed, to reduce the risk of serious bodily injury, including amputation, from moving parts inside the air motor housing. The chart below is specific to the air motor and pump. Refer to the other instruction manuals with the system to troubleshoot individual components. TROUBLE AREA: RESIN PUMP LEAKAGE TROUBLE AREA: HARDENER PUMP LEAKAGE 1. THROAT PACKING 2. PISTON PACKING 3. PISTON BALL CHECK 1. THROAT PACKING 2. PISTON PACKING 3. PISTON BALL CHECK Observe the gauge readings during the stroke direction indicated by the bold arrow, and immediately after closing the manifold. 22 308224 RESIN PUMP HARDENER PUMP RESIN PUMP HARDENER PUMP FALLING RISING RISING FALLING TROUBLE AREA: RESIN PUMP LEAKAGE TROUBLE AREA: HARDENER PUMP LEAKAGE 1. THROAT PACKING 2. FOOT VALVE BALL CHECK 1. THROAT PACKING 2. FOOT VALVE BALL CHECK RESIN PUMP HARDENER PUMP RESIN PUMP HARDENER PUMP FALLING RISING RISING FALLING Troubleshooting Problem System won’t run or stops while running. Solution Air pressure or volume too low. Increase, check air compressor. Closed or restricted air line or air valve. Open or clean as required. Fluid valves closed. Open fluid valves. Clogged fluid hose. Replace fluid hose. Air motor worn or damaged. Service air motor. See instructions in separate manual 306982. Displacement pump stuck. Service pump. See instructions in separate manual 307944 or 684004. Fluid containers are empty.** Check often – keep filled. Air in fluid lines.** Purge, check connections. Displacement pump parts worn or damaged. Service pump. See instructions in separate manual 307944 or 684004. Pump operates but resin output pressure drops during upstroke.* Dirty, worn or damaged resin pump piston valve. Clean, service pump. See instructions in separate manual. Worn or damaged resin pump piston packings. Replace. Pump operates but resin output pressure drops during downstroke. Dirty, worn or damaged resin pump n intake valve. Clean, service pump. See instructions in separate manual 307944 or 684004. Pump operates but resin output pressure drops during both strokes.* Dirty, worn or damaged resin pump piston valve. Clean, service pump. See instructions in separate manual 307944 or 684004. Fluid supply low.** Refill or change container. Pump operates but hardener output pressure drops during upstroke.* Dirty, worn or damaged resin pump intake valve. Clean, service pump. See instructions in separate manual 307944 or 684004. Worn or damaged hardener pump piston packings. Replace. Pump operates but hardener output pressure drops during downstroke.* Dirty, worn or damaged hardener pump intake valve. Clean, service pump. See instructions in separate manual 307944 or 684004. Pump operates but hardener output pressure drops during both strokes. Dirty, worn or damaged hardener pump intake valve. Clean, service pump. See instructions in separate manual 307944 or 684004. Fluid supply low.** Refill or change container. Fluid leaks around fluid pump packing nut. Loose packing nut or worn throat packings. Tighten, replace. Relief valve opens too soon or won’t close. Relief valve needs adjusting or is damaged. Adjust, service pump. See instructions in separate manual 307944 or 684004. System speeds up or runs erratically. * Cause Fluid ratio will be wrong. ** Purge all air out of the system before proportioning the fluids. 308224 23 Service – Displacement Pump Removal and Replacement 33 Stop the pump at the bottom of its stroke. HARD RES Thoroughly flush the system with a solvent which is compatible to the fluid being pumped, then follow the Pressure Relief Procedure on page 21. The Flushing procedure is on page 17. CAUTION If you are changing to a different type of fluid, completely clean all of the equipment and hoses, making sure that no fluid remains in any part of the system. 125 308224 RES 24 HARD 2. For Three Displacement Pump Models Only Unscrew the swivel union (33) from the bottom of the center displacement pump. Unscrew the swivel unions (126) from the outer displacement pumps. Remove the supply manifold (125) from the outer pumps. Unscrew the straight union (39) from the center displacement pump. See Fig. 21. RES Remove the fluid outlet hoses from the displacement pumps. 1. For Two Displacement Pump Models Only Unscrew the swivel unions (33) from the bottom of the displacement pumps. See Fig. 20. 33 Fig. 20 41 39 126 Fig. 21 33 Service – Displacement Pump Disassembly 1. Remove the locknuts (113) from the top of the yoke (114) of the two outer displacement rods. See Fig. 22. Unscrew the outer locknuts (122) from the top of the tie plate (123) on the two displacement pumps. Use a screwdriver and hammer to loosen. NOTE: The tie rods (111) shown in Fig. 22 are removed from the tie plate (121) for clarity only and do not require removal. 2. Remove the two outer pumps from the tie plate. Remove the washers (115) from the rods of each pump. 3. Three Displacement Pump Models Only. Using a wrench on the flats of the center pump’s displacement rod, screw the rod out of the yoke (114). See Detail B in Fig. 22. Remove the pump from the yoke (114) then the washer (115) from the rod on the pump. 4. Refer to the appropriate instruction manual for servicing the displacement pump. 113 1 111 115 114 122 123 1 122 Torque to 53–67 ft-lb (72–91 NSm) 121 1 DETAIL B C Fig. 22 Reassembly 1. Three Displacement Pump Models Only. Slide the center displacement pump rod through the tie plate (121), center locknut (123), and washer (115). Thread the displacement rod into the yoke (114) by turning the complete cylinder. Use a wrench on the flats of the displacement rod for final tightening. Torque to 53–67 ft-lb (72–91 NSm). Push the cylinder up into place in the tie plate and install the center locknut (123). 2. All pumps Slide the outer two displacement pump rods through the tie plate (121), outer locknuts (122), and washers (115). Install the locknuts (113) loosely on the displacement rods. Push the cylinders up into place in the tie plate and install the outer locknuts (122). 3. Move the air motor to the bottom of its stroke. Check for movement of the air motor yoke at each displacement rod. With the rods centered, tighten the locknuts (113) securely and torque to 53–67 ftlbs (72–91 NSm). 4. Tighten the throat packing nut just enough to prevent leakage, no tighter. 5. Reconnect the swivel unions to the pumps. Hold the intake valve (C) steady with a wrench to prevent from turning. 308224 25 Parts – Bare, Two Pumps Models 231643–231646 101 113 1 102 114 103 111 3 104 3 115 105 122 106 107 121 108 107 2 116 109 105 110 1 112 26 1 Torque to 53–67 ft-lb (72–91 NSm) 2 Apply anaerobic sealant and torque to 100–200 ft-lb (135–270 NSm) 3 Torque to 14–26 ft-lb (19–35 NSm) 4 Label 308224 4 118 4 HARD 120 RES 119 117 02903 Parts – Bare, Two Pumps Models 231643–231646 Ref. No. Part No. 101 207352 102 168418 103 100018 104 100017 105 100101 106 107 108 109 178471 100133 100307 168453 110 168454 111 168455 Description Qty. PRESIDENT AIR MOTOR see manual 306982 PLATE, pump adapter LOCKWASHER, 1/2 in. SCREW, hex cap head, 1/2–13 unc (2a) x 1-1/2 in. SCREW, hex cap head, 3/8–16 unc (2a) x 1.0 in. PLATE, mounting LOCKWASHER; 3/8 in. NUT, hex; 3/8–16 unc (2b) NUT, shoulder, 1-1/8–18 unef (2b) PUMP CONNECTING ROD TIE ROD; 8.937 in. (227 mm) long shoulder to shoulder Ref. No. 119 Model 1 1 3 Ref. No. Part No. 112 101946 113 101926 3 114 164414 115 164416 116 101712 7 1 7 4 117 118 119 120 1 1 121 164413 122 164417 188975 188974 see table see table Description Qty. PIN, cotter, 0.116 OD x 1–1/2 in. LOCKNUT 1/2–20 unf w/nylon insert YOKE, connector tube WASHER, flat, 1/2 in. LOCKNUT, 5/8–11 unc (2b) w/nylon insert LABEL, resin LABEL, hardener RESIN DISPLACEMENT PUMP HARDENER DISPLACEMENT PUMP TIE PLATE LOCKNUT, outer 1 2 1 2 4 1 1 1 1 1 2 4 Ref. No. 120 RESIN PUMP See this manual for parts 231643 222012 307944 222012 307944 231644 222015 307944 222015 307944 231645 222017 307944 222017 307944 231646 222019 307944 222019 307944 HARDENER PUMP See this manual for parts 308224 27 Parts – Bare, Three Pumps Models 231657, 231658, and 231663 101 3 102 113 103 114 104 111 105 106 122 108 123 107 122 109 105 110 112 1 116 121 117 RES HARD RES 120 118 4 117 4 124 125 124 119 1 Torque to 53–67 ft-lb (72–91 NSm) 2 Apply anaerobic sealant and torque to 100–200 ft-lb (135–270 NSm) 3 Torque to 14–26 ft-lb (19–35 NSm) 4 Label 5 Apply stainless steel pipe sealant to all threaded connections. 28 308224 3 115 107 2 1 126 5 02904 Parts – Bare, Three Pumps Models 231657, 231658, and 231663 Ref. No. Part No. 101 207352 102 168418 103 100018 104 100017 105 100101 106 107 108 109 178471 100133 100307 168453 110 168454 111 168455 112 101946 113 101926 Description PRESIDENT AIR MOTOR see manual 306982 PLATE, pump adapter LOCKWASHER, 1/2 in. SCREW, hex cap head, 1/2–13 unc (2a) x 1-1/2 in. SCREW, hex cap head, 3/8–16 unc (2a) x 1.0 PLATE, mounting LOCKWASHER; 3/8 in. NUT, hex; 3/8–16 unc (2b) NUT, shoulder, 1-1/8–18 unef (2b) PUMP CONNECTING ROD TIE ROD; 8.937 in. (227 mm) long shoulder to shoulder PIN, cotter, 0.116 OD x 1–1/2 in. LOCKNUT; 1/2–20 unf w/nylon insert Ref. No. 119 MODEL Qty. 1 1 3 3 7 1 7 4 1 1 Ref. No. Part No. 114 115 116 164414 164416 101712 117 118 119 120 121 122 123 124 125 126 4 1 Description Qty. YOKE, connector tube WASHER, flat, 1/2 in. LOCKNUT, 5/8–11 unc (2b) w/nylon insert 188975 LABEL, resin 188974 LABEL, hardener see table RESIN DISPLACEMENT PUMP see table HARDENER DISPLACEMENT PUMP 164413 TIE PLATE 164417 OUTER LOCKNUT 164417 CENTER LOCKNUT 100345 PLUG, pipe, 11–1/2 npt(f) 208334 SUPPLY MANIFOLD 156589 SWIVEL UNION, 90_, 3/4 npt (m x f) 1 3 4 1 1 2 1 1 2 1 2 1 2 2 Ref. No. 120 See this RESIN HARDENER See this manual for PUMP Qty 2 manual for PUMP parts parts 231657 222017 307944 222017 307944 231658 222019 307944 222019 307944 231663 222012 307944 222019 307944 308224 29 Parts – Wall Mount, Two Pumps Models 231593 and 231595 1 Apply stainless steel pipe sealant to all threaded connections except at swivels. 2 Included with bare pump 2 3 1 4 5 6 11,12 9 2 10 7 8 13 14 2 1 1 18 17 22 16 21 1 15 20 19 38 1 23 1 24 25 37 11, 28 13 29 1 30 1 31 1 26 1 27 36 35 1 34 37 33 32 30 308224 1 1 02905A Parts – Wall Mount, Two Pumps Models 231593 and 231595 Ref. No. Part No. 1 see table 2 100960 3 161262 4 5 100840 206197 6 7 8 113269 158491 157416 9 159239 10 11 12 13 236061 188596 188975 102814 14 217378 15 157676 16 155699 17 161037 18 19 20 21 22 see table 159239 111591 100016 100021 23 215626 24 156823 Description Qty. BARE PROPORTIONAL PUMP see parts on page 27 1 PRESSURE GAUGE, 0–2000 psi (14 MPa, 140 bar) 1 SWIVEL UNION, 90_, 1/4–18 npt (f) x 1/2 npt 1 ELBOW, street, 1/4–18 npt (m x f) 1 AIR REGULATOR, 300 psi (2.1 MPa, 21 bar) 1 SHUTOFF VALVE, 1/2 npt (m x f) 1 NIPPLE, 1/2 npt short 1 SWIVEL UNION, 90_, 1/2 npt (m x f) 1 NIPPLE, pipe, reducing 1/2–14 npt x 3/8–18 npt (f) 1 BRACKET, mounting 1 MANIFOLD BLOCK 3 LABEL, resin 1 PRESSURE GAUGE, used for hardener and resin 1 HOSE, nylon, w/spring guards, cpld 3/8–18 npt (mbe) x 30 in., 3/8 in. ID 1 SWIVEL UNION, 90_, 1/4–18 npt (m x f) 1 ELBOW, street, 3/8–18 npt (m x f), carbon steel 2 90_ SWIVEL, 1/2 npte x 3/8 npsmi 2 PRESSURE RELIEF VALVE 2 NIPPLE, 1/2 x 3/8 npte 2 WASHER, flat, 1/4 in. 4 LOCKWASHER, 1/4 in. 4 SCREW, hex cap head, 1/4–20 unc (2a) x 1 in. 4 MIXER MANIFOLD See manual 307400 1 SWIVEL UNION, 1/4 npt(m) x 1/4 npt(f) 2 Ref. No. Part No. 25 26 108233 164259 27 235905 28 29 30 31 32 188974 101748 206962 100483 105770 33 16X233 34 101078 34a 35 36 37 187758 160032 102735 157785 38 236249 39 237569 Description Qty. NEEDLE (DRAIN) VALVE ELBOW, street, 3/8–18 npt (m) 1/4–18 npt (f) HOSE, cpld, 3/8–18 npt x 30 in. mbe, 0.318 ID, PTFE LABEL, hardener PLUG, pipe, 3/8–18 npt(f), sst CHECK VALVE, 3/8 npt (mbe) TEE, pipe, 3/8–18 npt (f) FLUID PRESSURE GAUGE, 0–1000 psi (6.9 MPa, 69 bar) 1/4 npt ELBOW, street, 90_, 1/4–18 npt(f) x 3/4–14 npt (m x f) FLUID STRAINER, 3/4 npt Includes item 34a . GASKET, PTFE NIPPLE, 3/4 npt BALL VALVE, 3/4–14 npt (f) SWIVEL UNION, 3/4 nps (f) x 3/4 npt (m) DRAIN KIT ASSEMBLY see parts on page 37 GROUND WIRE AND CLAMP; not shown 2 2 1 1 2 2 2 2 1 2 2 2 3 2 1 Ref. No. 1 Ref. No. 18 Bare Pump Pressure Relief Valve 231593 231643 237112 231595 231645 237062 MODEL * Pressure Gauge Descriptions 105770 102814 0–1000 psi (6.9 MPa, 69 bar) 1/4–18 npt 0–5000 psi (31 MPa, 310 bar) 1/4–18 npt 308224 31 Parts – Wall Mount, Three Pumps Models 231607 and 231613 Apply stainless steel pipe sealant to all threaded connections except at swivels 1 2 Included with bare pump 3 11,12 2 5 1 4 19 13 9 6 2 7 10 8 2 14 1 18 17 1 16 22 1 15 21 20 42 38 23 11, 28 1 30 40 29 1 30 1 24 25 1 41 26 37 1 31 1 26 1 27 39 36 37 35 1 34 33 41 32 308224 1 1 02906A Parts – Wall Mount, Three Pumps Models 231607 and 231613 Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Part No. Description Qty. see table BARE PROPORTIONAL PUMP see parts on page 29 1 100960 PRESSURE GAUGE, 0–2000 psi (14 MPa, 140 bar) 1 161262 SWIVEL UNION, 90_, 1/4–18 npt(f) x 1/2 npt 1 100840 ELBOW, street, 1/4–18 npt (m x f) 1 206197 AIR REGULATOR, 300 psi (2.1 MPa, 21 bar) 1 107142 SHUTOFF VALVE, 1/2 npt (m x f) 1 158491 NIPPLE, 1/2 npt short 1 157416 SWIVEL UNION, 90_, 1/2 npt (m x f) 1 159239 NIPPLE, pipe, reducing 1/2–14 npt x 3/8–18 npt (f) 1 236061 BRACKET, mounting 1 188596 MANIFOLD BLOCK 3 188975 LABEL, resin 1 see table PRESSURE GAUGE, used for hardener and resin 3 217378 HOSE, nylon, w/spring guards; cpld 3/8–18 npt(mbe) x 30 in.; 3/8 in. ID 2 157676 SWIVEL UNION; 90_; 1/4–18 npt(m x f) 1 155699 ELBOW, street; 3/8–18 npt(m x f); carbon steel 2 161037 SWIVEL; 90_; 1/2 npte x 3/8 npsmi 2 see table PRESSURE RELIEF VALVE 2 166469 NIPPLE; 3/4 hex; 3/8–18 npt(mbe); sst 1 111591 WASHER, flat; 1/4 in. 6 100016 LOCKWASHER; 1/4 in. 6 100021 SCREW, hex cap head, 1/4–20 unc (2a) x 1 in. 6 215626 MIXER MANIFOLD See manual 307400 1 156823 SWIVEL UNION, 1/4 npt(m) x 1/4 npt(f) 2 Ref. No. Part No. 25 26 108233 164259 27 235905 28 29 30 31 33 188974 101748 206962 100483 16X233 34 101078 34a 35 36 37 187758 160032 102735 157785 38 236249 39 188597 40 41 101742 105770 42 159239 Description Qty. NEEDLE (DRAIN) VALVE ELBOW, street, 3/8–18 npt (f) 1/4–18 npt (f) HOSE, cpld, 3/8–18 npt x 30 in. mbe, 0.318 ID, PTFE LABEL, hardener PLUG, pipe, 3/8–18 npt(f), sst CHECK VALVE, 3/8 npt (mbe) TEE, pipe, 3/8–18 npt (f) ELBOW, street, 90_, 1/4–18 npt(f) x 3/4–14 npt (m x f) FLUID STRAINER, 3/4 npt Includes item 34a . GASKET, PTFE NIPPLE, 3/4 npt BALL VALVE, 3/4–14 npt (f) SWIVEL UNION, 3/4 nps (f) x 3/4 npt (m) DRAIN KIT ASSEMBLY see parts on page 37 ADAPTER; 3/4–14 npt(f) x 3/4–14 npsm BUSHING; 3/8 npt x 1 in. PRESSURE GAUGE; 0–1000 psi (6.9 MPa, 69 bar); 1/4–18 npt NIPPLE; 1/2 x 3/8 npte 2 2 1 1 2 2 2 1 2 2 2 3 2 1 1 2 2 Ref. No. 1 Ref. No. 13 Ref. No. 18 Bare Pump Pressure Gauge* Pressure Relief Valve 231607 231657 102814 237112 231613 231663 105770 237061 Model * Pressure Gauge Descriptions 105770 102814 0–1000 psi (6.9 MPa, 69 bar) 1/4–18 npt 0–5000 psi (31 MPa, 310 bar) 1/4–18 npt 308224 33 Parts – Stand Mount, Two Pumps Model 231618 1 1 2 Apply anaerobic sealant and torque to 10–15 ft-lb (14–20 NSm) See parts on pages 36 and 37 50 53 51 1 52 2 38j 54 51 50 55 02907A 34 308224 Parts – Stand Mount, Two Pumps Models 231618 Ref. No. Part No. 1 231593 50 51 52 53 100321 100018 217297 100679 54 55 178473 168422 Description WALL MOUNT PUMP see parts on page 31 NUT, hex, 1/2–13 unc LOCKWASHER, 1/2 in. LEG, frame SCREW, hex cap head, 1/2–13 unc (2a) x 3–1/2 in. BRACE, frame CAP, square tube Qty. 1 6 6 2 6 1 6 308224 35 Parts– Stand Mount, Three Pumps Models 231632 and 231638 1 1 Apply anaerobic sealant and torque to 10–15 ft-lb (14–20 NSm) 50 53 51 1 52 38a 38b 38e 38c 38d 53 1 38j 54 38f 38g 38h 51 50 55 02908A 36 308224 Parts – Stand Mount, Three Pumps Models 231632 and 231638 Ref. No. 1 50 51 52 53 54 55 Part No. Description Ref. No. 1 Qty. see table WALL MOUNT PUMP see parts on page 33 100321 NUT, hex, 1/2–13 unc 100018 LOCKWASHER, 1/2 in. 217297 LEG, frame 100679 SCREW, hex cap head, 1/2–13 unc (2a) x 3-1/2 in. 178473 BRACE, frame 168422 CAP, square tube 1 6 6 2 Model Wall Pump 231632 231607 231638 231613 6 1 6 Ref No. 38 Drain Valve Kit Supplied with the Wall Mount units and Stand Mount units Ref. No. Part No. Description 38a 38b 38c 38d 190738 112279 236272 100022 38e 38f 38g 38h 38j 112278 100016 111591 100015 113187 . TUBE, nylon, 36 in. x 1/2 in. OD . BOTTLE . HOLDER, bottle . SCREW, hex cap head, 1/4–20 unc (2a) . TIE WRAP . LOCKWASHER, 1/4 in. . WASHER, flat, 1/4 in. . NUT HEX, 1/4–20 unc (2b) . CONNECTOR, female, tube Qty. 1 1 1 1 1 1 1 1 1 308224 37 Accessories Parts for Installing Optional Heaters Viscon HP Fluid Heaters The following components are recommended to install the heaters as instructed on page 13. Two displacement pump models need Items 201 to 204. Three displacement pump models need Items 201 to 205 and an additional resin and hardener hose of an appropriate length. Style A Ref. No. Model 245863, 240 Volt, Stainless Steel Part No. 201 — 202 155494 203 161037 204 235905 205 217378 Description Qty. FLUID HEATER; select from list to the right SWIVEL UNION, 90_, 3/8–18 npt (m x f) SWIVEL UNION, 90_, 1/2 npt(f) x 3/8–18 nps(m) HOSE, cpld; hardener, 3/8–18 npt x 30 in. mbe 0.318 ID PTFE HOSE, nylon, w/spring guards; resin, cpld 3/8–18 npt x 30 in. (mbe) 3/8 in. ID 4000 psi (28 MPa, 276 bar) Maximum Working Pressure 85_ – 220_ F (29_ – 104_ C) Temperature Range 4000 psi (28 MPa, 276 bar) Maximum Working Pressure 85_ – 220_ F (29_ – 104_ C) Temperature Range 2 2 2 Model 245864, 480 Volt, Stainless Steel 4000 psi (28 MPa, 276 bar) Maximum Working Pressure 85_ – 220_ F (29_ – 104_ C) Temperature Range 1 1 201a 201b 201 Model 245848, 120 Volt, Stainless Steel Style B Model 226819, 240 Volt Aluminum and Zinc 202 204 3000 psi (21 MPa, 210 bar) Maximum Working Pressure 80_ – 190_ F (26_ – 88_ C) Temperature Range Style A Model 245848 shown 205 203 02891 38 308224 Style B Model 226819 shown Accessories Parts for Installing Optional Solvent Pump Ref. No. Part No. 301 151519 302 303 304 305 306 OR 307 308 309 310 311 312 313 314 315 316 Description Ref 5 301 302,303 Qty. NIPPLE, reducing, 1/4–19 nptm x 1/8–27 nptm 111913 COUPLING, hose, 1/4–18 npsm, w/spring guard, stainless steel 061132 HOSE, nylon 1/4 in. ID x 36 in. long 206264 VALVE, needle, 1/4–18 npt (m) 158841 ADAPTER, 1/4–18 unc (f) x 3/8–18 npt (m), carbon steel 217523 10:1 RATIO MONARK PUMP for heavy viscosity system 208470 5;1 RATIO MONARK PUMP for light viscosity system 157350 ADAPTER, 3/8–18 npt x 1/4–18 npt (mbe) 155541 SWIVEL UNION, 90_, 1/4 npt (f x m) as needed FLUID HOSE 207365 BRACKET, mounting 241037 BALL VALVE 207484 SUCTION TUBE ASSEMBLY, 3/4 npt 100101 SCREW, hex cap head, 3/8–16 unc (2a) x 1 in. 100133 LOCK WASHER, 3/8 in. 100307 NUT, hex, 3/8–16 unc (2b) 100132 WASHER, flat, 7/16 in. A 2 306 305 2 1 1 301 304 1 1 1 1 1 307 308 309 310 B 316 315 1 1 1 4 4 4 4 A 314 313 312 311 B 02902B Miscellaneous Accessories Nitrogen Regulator Kit, 207638 Maintains a nitrogen head on the supply drum to protect materials from moisture. Kit includes two 6 ft x 1/4 in. (1.8 m x 6 mm ) hoses, control box with gauge, regulator, and relief valve. Inlet: 1/4 in. npt(m). Outlet: 3/4: npt (m). ISO Pump Oil A highly refined, special purpose throat seal lubricant the minimal reaction with Isocyanates. 217374 16 oz (0.13 liter) container 218656 4 gallon (18.14 liter) container Graco Throat Seal Liquid Non-evaporating liquid for wet-cup 206995 0.95 liter (1 quart) 206996 3.8 liter (1 gallon) 308224 39 Accessories Air Control Accessories Fluid Control Accessories Bleed-Type Master Air Valve Fluid Filter 300 psi (2.1 MPa, 21 bar) Maximum Working Pressure 5000 psi (35 MPa, 350 bar) Maximum Working Pressure Relieves air trapped in the air line between the pump air inlet and this valve when closed. 60 mesh (250 micron) screen. 107141 Model 218029 Carbon steel bowl and support 3/4 npt(m) inlet x 3/4 npt(f) outlet 107142 1/2 npt(m) inlet x 1/2 npt(f) outlet Model 223160 Stainless steel bowl and polyethylene support Air Line Filter 106149 250 psi (1.8 MPa, 17.5 bar) Maximum Working Pressure Filters harmful dirt and moisture from the compressed air supply. 1/2 npt(f) inlet and outlet. See instruction manual 308169. Air Line Lubricator 214848 250 psi (1.8 MPa, 17.5 bar) Maximum Working Pressure Provides automatic lubrication for the air motor. 0.48 liter (16 oz) bowl capacity. 1/2 npt(f) inlet and outlet. See instruction manual 308169. Fluid Shutoff Valve 5000 psi (35 MPa, 350 bar) Maximum Working Pressure Model 235992 stainless steel with PTFE seals 1/4 x 3/8 nps (mbe) Model 223960 carbon steel with PTFE seals 3/8 npt (mbe) Model 214037 carbon steel with PTFE seals 1/4 npt (mbe) Static Mixing Units 3000 psi (21 MPa, 210 bar) Maximum Working Pressure Pump Runaway Valve 224040 120 psi (0.8 MPa, 8.4 bar) Maximum Working Pressure Shuts off air supply to the pump if the pump accelerates beyond the pre-adjusted setting due to an empty supply container, interrupted fluid supply to the pump, or excessive cavitation. 3/4 npt(f) inlet and outlet. Includes optional 90_, 3/4 npsm swivel outlet fitting. See instruction manual 308201. Air Regulator 206197 These units consist of a tube with helical interior elements which thoroughly blend base and catalyst materials into the proper mix. Model 500639 14 in. (356 mm) long, 5/16 in. (8 mm) ID, 27 Elements 3/8 npt order fittings separately Model 500586 25 in. (635 mm) long, 0.44 in. (11 mm) ID, 32 Elements 1/2 npt order fittings separately 300 psi (2.1 MPa, 21 bar) Maximum Working Pressure Model 502028 29 in. (736 mm) long, 0.8 in. (20 mm) ID, 24 Elements 3/4 npt Controls air pressure to feed, solvent, or proportioning pumps. 1/2 npt inlets and outlets, with (2) 1/4 npt pressure gauge outlets. 40 308224 Model 945917 25 in. (635 mm) long, 2–1/2 in. (64 mm) OD, 10 Elements 1 in. npt (m x f) Notes 308224 41 Dimensions Mounting Hole Layout for Air Motor 7 2 1 3 1 2 3 2 6 2 3 3 0288 4A 5 4 1 14–3/4 in. (375 mm) 5 30–1/4 in. (768 mm) 2 32–3/4 in. (832 mm) 6 11 in. (279 mm) 3 28–1/4 in. (718 mm) 7 12–1/2 in. (318 mm) 4 17–3/4 in. (451 mm) 42 308224 4 1 0.438 in. (11.12 mm) diameter 2 3.712 in. (92.28 mm) 3 7.424 in. (188.66 mm) 4 9.75 in. (247.65 mm) diameter Technical Data Pumps Air operating range Air consumption 40–100 psi (0.3–0.7 MPa, 3–7 bar) See example below Fluid inlet size 3/4 npt Fluid outlet size 3/8 npt Air inlet size 3/4 npt Maximum fluid outlet pressure Maximum fluid inlet pressure Wetted parts 3000 psi (21 MPa, 210 bar) 250 psi (1.7 MPa, 17 bar) Stainless steel, Tungsten Carbide, Chrome plating, Carbon steel, PTFE, Ultra-high molecular weight polyethylene Air Consumption Example: When the air pressure to the pump is 60 psi (0.4 MPa, 4 bar) and you are dispensing 1 gal. (3.8 liter) of mixed fluid per minute, air volume used, in cfm, will be about the same as the larger pressure ratio figure of your pump. See page 4 for pressure ratios of pumps. Manifold assemblies Manifold outlets Hoses 3/8 npt 3/8 in. ID, PTFE, cpld 3/8 npt(m) 4000 psi (28 MPa, 276 bar) maximum working pressure 3/8 in. ID, Nylon, cpld 3/8 npt(m) 3000 psi (21 MPa, 210 bar) maximum working pressure Automatic pressure relief valves wetted parts 303 stainless steel,Tungsten carbide, fluoroelastomer Sound Sound pressure levels (dBa) (Input air pressures at 15 cycles/min.) 73.6 dB(A) at 40 psi (0.3 MPa, 2.8 bar) 78.3 dB(A) at 70 psi (0.5 MPa, 4.8 bar) 80.9 dB(A) at 100 psi (0.7 MPa, 7 bar) Sound power levels (dBa) (Input air pressures at 15 cycles/min.) 87.4 dB(A) at 40 psi (0.3 MPa, 2.8 bar) 92.1 dB(A) at 70 psi (0.5 MPa, 4.8 bar) 94.6 dB(A) at 100 psi (0.7 MPa, 7 bar) Tested in accordance with ISO 9614–2. 308224 43 Graco Standard Warranty Graco warrants all equipment 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 procedures concernées. Graco Information For the latest information about Graco products, visit www.graco.com. TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers to identify the distributor closest to you: 1–800–328–0211 Toll Free 612–623–6921 612–378–3505 Fax 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. For patent information, see www.graco.com/patents. Original instructions. This manual contains English. MM 308224 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea 44 GRACO INC. AND SUBSIDIARIES S P.O. BOX 1441 S MINNEAPOLIS MN 55440–1441 S USA Copyright 1994, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revised December 2013 308224
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