Graco 309024C User's Manual
Contents
1. Instructions G GRACO HYDRA CAT VARIABLE RATIO Proportioning Pumps 309024C Includes Automatic Pressure Relief Valves Check Valves Pressure Gauges and Regulators Basic Operation for Use with Configured Models Important Safety Instructions Read all warnings and instructions in this manual Save these instructions A WARNING Plural Component Materials Hazard Graco Inc does not manufacture or supply any of the Mounting as Shown reactive chemical materials that may be used in this Monark Air Motor and equipment and is not responsible for their effects Be Standard Manifold Shown cause of the vast number of chemicals that could be used and their varying chemical reaction before us ing this equipment the buyer and the user should de termine all facts relating to the materials used includ ing any of the potential hazards involved Particular inquiry and investigation should be made into the po tential dangers relating to toxic fumes fires explo sions reaction times and exposure of human beings to the individual components or their resultant mix tures Graco assumes no responsibility for loss dam age expense or claims for bodily injury or property damage direct or consequential arising from the use of such chemical components PROVEN QUALITY LEADING TECHNOLOGY GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 1999 Graco Inc is registered to I2. To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 15 1 Relieve the pressure 2 Flush the unit as instructed on page 16 before setting the pump 3 Remove the safety panel 39 See Fig 8 on page 17 4 Loosen the four capscrews 16 holding the secondary pump s in place 5 Open the fluid outlet and lift or push the lever arm 49 to the horizontal position 6 Move the secondary pump so that the line on the index clamp 30 is at the desired setting on the scale 26 7 With the secondary pump as vertical as possible tighten the four screws 16 to 50 ft lb 78 N m 8 Replace the safety panel 39 14 309024 Fig 6 30 16 m7 d 4 B 16 jh WER i D gt 02369 Operation Pressure Relief Procedure A WARNING SKIN INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying dispensing acciden tally 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 are instructed to relieve the pressure stop spraying dispensing check or service any of the system equipment or install or clean the spray tip nozzle 1 Lock the gun valve trigger safety 2 Close the bleed type m
3. 3 Close the mixer manifold 4 Open the sample valve 119 on the secondary pump side approximately three turns Open the sampling valve on the primary pump side just one turn This prevents the pressure from building up on the secondary pump which would cause the relief valve 46 to open O DAN 02366A Fig 8 5 Place a grounded metal pail under the sampling valves 6 Open the mixer manifold Use the sampling valves to adjust the pressures to your normal operating pressure NOTE The pressure must be within 20 of your normal operating pressure to get a useable sample 7 Close the mixer manifold Put the sampling containers under the sampling valves 8 Open the mixer manifold Check the ratio Make sure the pressure is within 20 of the normal operating pressure Close the mixer manifold when enough fluid has been dispensed into the sampling containers NOTE If the pressure is not within 20 of the normal operating pressure follow the flushing procedure on page 16 and then take another sample If the sample ratio is incorrect there is a problem with the sample valves secondary pump setting or the pump operation Check the pump setting or service the sampling valves or pump 309024 17 Troubleshooting Troubleshooting Techniques Because the pumps are mechanically linked the action of one pump can affect the readings of the second pump Therefore the key to succ
4. All A04 A06 A09 A12 A14 D02 F06 A04 A06 A09 A12 A14 D02 F06 A09 A12 A14 D02 F06 686632 A09 A12 A14 D02 F06 686632 A04 A06 All others All All All All All All All All 309024 37 Dimensions 02366A Four sockets for casters See Accessories 38 309024 A 000 rom Height President cose 48 5 1232 mm VISCOUNL es rnit s 48 5 1232 mm Monark ssssseseu 45 6 1156 mm Bulldog sssus 55 5 1410 mm Length a carmi ie ph REDE 35 889 mm Widtli 5i nperese xviii 18 457 mm Ait Inlet epi inn 1 2 npt f has four 1 4 npt f plugged outlets Fluid Inlets Two 3 4 npsm f swivel has 1 4 npt f plugged cleanout port Solvent Inlets 2 0000 1 2 npt m Fluid Outlet 000020 00 1 2 npt m Valve Outlets 04 Two 1 4 npt m Technical Data Stroke Effective Motor Weight Length Area 19 Ib 4in 14 19 Sq in President 8 6 kg 102 mm 91 55 cm Monark 5 ak eri ier d Wetted Parts See Configurator Product Order Form 309025 78 lb 4 75 in 7 07 Sq in Bulldog 35 1 kg 121 mm 45 61 cm 18 5 Ib 4 in 7 07 Sq in Viscount I 83 kg 102 mm 45 61 cm Maximum Fluid Working Pressure Maximum Pump Air Input Pres alll Model sure 250 bar 25 0 MPa 3600 psi 12 5 bar 1 25 MPa 180 psi 125 bar 12 5 MPa 1800 psi 1
5. S EN ISO 9001 Table of Contents Warnings euer et Bu deua Guetta gite eds 3 System Information 0000c cece lessen 5 Ratio Adjustment 0 cece eee 10 Determining the Ratio 02 000s 11 Set the Ratio sargen daa cece eee 12 Calculate the Ratio Setting 13 Setting the Secondary Pump s 14 Operations si overs i Vases en ing oes 15 Troubleshooting 0 c ce eee eee eee eee 18 SOVICE Erste patte rece ebrei er tcc 20 Required Service Tools ssuu 20 Bearing and Pump Lubrication 20 Air Lubrication 0 0 0 cee eee 20 Detecting Bearing and Pin Wear 20 Removing the Lever Arm from the VRHC Frame sssssssss 21 Determining Which Pin and or Bearing is Worn ssuu 22 Fitting the Pins into the Bearings 22 Storage of Spare Pins and Bearings 22 Removing the Secondary Pump and or the Bearings and Pins 22 Replacing the Secondary Pump and or the Bearings and Pins 24 Removing the Primary Pump and or the Lower Bearing and Pin cee eee eee 25 Replacing the Primary Pump and or Bearing and Pins 27 Replacing the Lever Arm on the Frame 28 PAIS erik eim Lee Lp qu 30 Dimensions iere In eR X Y Rer 38 Technical Data 0 2 c eee eee ee 39 Graco Warranty 00 cece eee eee eee 40 Graco Info
6. UNION 90 1 2 npt m x 1 2 npsm f swivel 1 SWIVEL UNION straight 3 4 npt m x 1 2 npsm f swivel BUSHING 3 8 npt f x 1 2 npt m GROMMET NIPPLE 1 2 npt LABEL WARNING MANIFOLD air o MN Ref No Part No 38 177118 39 177119 40 177120 424 177144 45 107142 47 214652 48 H53806 51 062035 55 180673 56 100179 57 100718 58 180674 60 223778 61 164672 Description PANEL safety PANEL safety PANEL safety LABEL WARNING AIR VALVE bleed type master HOSE buna s 1 2 in 13 mm ID coupled 3 8 npt mbe 1 5 ft 0 45 m long HOSE nylon 3 8 10 mm ID 3 8 npsm fbe 6 ft 1 8 m long MOLDING rubber BRACKET NUT 10 24 WASHER no 10 U BOLT 10 24 HOSE PTFE 1 4 in 6 mm ID coupled 1 4 npsm fbe 5 ft 1 8 m long ADAPTER 3 8 npt x 1 4 npsm mbe Qty KR ss n 1 1 1 8 feet 1 2 2 1 1 1 A Replacement Danger and Warning labels tags and cards are available at no cost 309024 35 All President Options Displacement Pump Combinations for Other Proportion Ratios See page 38 for adjustment ratio URRY p N Pump Combinations Proportion Volume OutputT At 100 psi 0 7 MPa 7 bar Ratio m l min si MPa bar Primary Secondary t gpm A part vt 222012 222015 1 2 1 to 5 6 1 1 10 to 0 70 1300 to 2200 4 2 to 2 6 9 to 15 90 to 152 222012 2220
7. lb 81 N m c Lubricate the support pin 35d with Gear Reducer Oil 43 Install the pin with the coun tersinks facing up into one side of the frame base 50 Place one nylon spacer 27d on the end of the support pin d Install the bearing 14d and manifold 32 and align them with the support pin 35d e Tap the pin in flush with the opposite side of the frame Align the second nylon spacer with the support pin and tap the pin all the way into the side of the frame base 50 f Tighten the two setscrews 17b onto the support pin 35d Torque to 35 in Ib 4 N m g Follow the procedure for replacing the primary pump on page 27 28 309024 Replacing the Lever Arm on the Frame A CAUTION Tolerances between the surface of the frame and bearing are very close Do not force the pin into place Check for burrs on the pin or in the VRHC frame if the pin does not slide into place Sand with 500 grit sandpaper between the countersinks NOTE Refer to Fig 18 for Steps 1 to 5 1 Screw the locknuts 2 onto the pivot bearing 15 2 Screw the pivot bearing into the frame base 50 Adjust the distance from the top of the support pin 33 to the bottom of the frame 50 to 26 125 664 mm 3 With the bearings at the correct height and parallel to each other torque the locknuts 2 to 60 ft Ib 81 N m 4 Place a generous amount of lubricant 43 onto the support pin and place the lever arm 49 over the
8. make reassembly diffi cult 309024 21 Service Determining Which Pin and or Bearing is Worn 1 Disassemble the VRHC After the pins and bear ings are removed wipe them off with a clean rag 2 Visually inspect the pins for scoring lines grooves and scratches on the area in contact with the bearing Then feel the surface of the pin for rough areas or a difference in size If these signs of wear are detected replace both the pin and bearing 3 To check the bearings hold the threaded part of the bearing in one hand and use the other hand to move the balls inside the bearing up and down If there is any noticeable movement replace the bearings Also check the bearings for roundness If a bearing appears to be out of round egg shaped replace it Fitting the Pins into the Bearings Tolerances between the surface of the pin and the bearings are very close Never force the pin into the bearing If the pin does not fit sand it from the end to just past the countersinks with 500 grit sandpaper See Fig 12 If the pin still does not fit return it to the factory for replacement If the pin needs replacement replace the bearing also Dri Fig 12 02373 Storage of Spare Pins and Bearings Completely coat spare pins and bearings with Graco Gear Reducer Oil 43 or the equivalent when storing these parts Never use grease 22 309024 Removing the Secondary Pump and or the Bearings and Pins 1 Flush the e
9. on both sides of the nominal ratio setting of 91 If the same primary and secondary pump models are used a 91 setting will give a 1 1 ratio If different pump models are used you must know the pump s effective area to determine the setting The displacement pumps effec tive areas are listed in Configurator Product Order Form 309025 12 309024 118 A2 N9 We 0096 HH EM m o o E EN N 123 124 a eo 02368 KEY Primary Stroke HH Lever Arm Index 4 102 mm Secondary Stroke Effective Area SP PP Index Setting Fig 5 Relationship Between Primary and Secondary Pump Moving the secondary pump closer to the primary pump to a lower index setting reduces the secondary stroke length reducing its fluid output Moving the secondary pump further from the priming pump to a higher index setting increases the secondary stroke length which increases its fluid output Calculate the Ratio Setting In this example A 5 1 ratio of base to catalyst is required The base primary pump Model e g 221074 effective area is 0 470 in 2 The catalyst secondary pump Model e g 221026 effective area is 0 278 in 2 To determine the base to catalyst setting a Multiply the primary pump s effective area by 91 nominal ratio setting 0 47 primary pump s effective area X 91 nominal ratio setting 42 77 answera b Multiply the catalyst pump s effecti
10. safety panels 38 39 40 See Fig 4 on page 10 Connect a grounded fluid hose X from the solvent flush pump to the 3 8 npt solvent flush inlet N of the mixer manifold Connect the Fluid Supply Lines Connect grounded fluid hoses to the 3 4 npt f inlet filter fittings R T If the unit will be pressure fed from separate supply pumps install a fluid pressure gauge at each inlet NOTE Pressurized fluid supplies must not exceed 1 4 the operating fluid pressure of the pump or 400 psi whichever is less Pressure above that level will feed through the pump and improper proportioning will result Connect the Static Mixer to the Manifold Connect the static mixer P to a grounded fluid hose and spray gun or dispensing valve to the end of the static mixer If multiple guns are used connect a manifold or pipe T to the bottom of the static mix tube and connect ball valves at each outlet Connect an applicator fluid hose to each ball valve IMPORTANT Each side must be flushed at each application to ensure the lines do not plug with cured material Tighten all fittings Replace the safety panels 38 39 40 8 309024 System Accessories Refer to Figures 1 and 2 and Accessories in Configu rator Product Order Form 309025 NOTE To ensure maximum pump performance be sure all accessories are properly sized to meet your system requirements In the air line install an air filter L to remove harmful dirt and moisture from
11. the VRHC as shown in Fig 14 If it does pin 34a not rotate the secondary displacement pump until it does and tighten the locknut 3 against a Place a generous amount of Graco Gear the inlet manifold Torque the locknut to 60 ft lb Reducer Oil 43 on the inside of the upper 81 N m bearing 14a and the surface of the support pin 34a b Replace the connecting rod assembly 117 14a 34a 31a onto the displacement rod and line up the cotter pin holes Insert the cotter pin 102 c Raise the lever arm 49 and place the A CAUTION support 31a under the proper slot b Slide the support 31a onto the bearing 14a Insert the support pin 34a with the counter sinks in place under the setscrew 17a holes Do not force the pin into place Check for burrs on d Push down the lever arm until the support fits the pin or in the VRHC frame if the pin does not slide into the slot If the support does not line up into place with the slot rotate it clockwise until it does c Tighten the setscrews 17a to 35 in Ib e Place the ratio index clamp 30 over the top of 4 N m These are 10 32 self locking screws the support 31a Insert the capscrews 16a If no drag is felt while turning replace the setscrews f Setthe index clamp 30 for the proper ratio and tighten the capscrews 16a d Place the support 31a in a vise and screw the connecting rod 117 onto the bearing 2 If replacing the lower bear
12. the end of a stroke Secondary displacement pump bottomed out because ratio index clamp was set too far out See below Adjust ratio index clamp Secondary displacement pump bottomed out because top pivot bearings are set too high Adjust bearings See Removing the Lever Arm from the VRHC Frame on page 21 309024 19 Service Required Service Tools Tool Use for 3 32 90 or T handle hex key All setscrews 3 4 open end wrench Clamp bolts and fluid hose on pump outlet 1 open end wrench Locknuts on capscrews 9 16 open end wrench Tie rod nuts 1 2 open end wrench Loosening tie rods from motor base 1 1 8 open end wrench Pivot bearing locknuts Adjustable open end wrench Tightening connecting rod to pumps Needle nose pliers Bending and pulling cotter pins Medium slotted screwdriver Removing shields Small hammer and 6 punch Tapping out pins Bearing and Pump Lubrication A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 15 1 Relieve the pressure 2 Insert one end of the nylon hose 52 into the wet cup 3 Pour Throat Seal Liquid 44 into the hose until the wet cup is full 4 Lubricate the VRHC periodically with Graco Gear Reducer Oil 43 If the pump is operating continu ously at 60
13. 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 war
14. 1 3 4 inch 44 mm SETSCREW 10 32 SPACER GAUGE designation SPACER 1 4 nylon CLAMP lower CLAMP top index SUPPORT pivot pin Qty ABO TINI mo CO n9 m mBem2025 Ref No PartNo Description Qty 32 177101 MANIFOLD inlet 2 33 177105 PIN pivot frame 1 34 177106 PIN pivot housing 2 35 177107 PIN pivot pump 2 36 177108 PLATE wear 2 424 177144 LABEL WARNING 4 44 206994 THROAT SEAL LIQUID not shown 8 ounces 49 215664 ARM lever 1 50 215665 FRAME BASE VRHC 1 52 061135 HOSE nylon not shown 1 5 feet 53 102790 SCREW 10 24 4 59 108038 SETSCREW 10 32 2 60 189559 CAP end 4 A Replacement Danger and Warning labels tags and cards are available at no cost 309024 33 Parts Unit Frame All Options WMU TIS h 51 02433A RS G WSS 34 309024 Unit Frame All Options Ref No 1 4 6 7 8 11 12 13 Part No 108036 100377 100737 100840 100960 108037 103836 104267 155470 157785 100081 158244 158491 177096 177117 Description Qty STUD fastener 12 SCREW slotted head 1 4 20 x 5 8 in 16 mm 2 PLUG pipe 1 2 npt 4 ELBOW street 1 4 npt m x f 1 GAUGE air pressure 0 200 psi 0 14 bar 1 NUT sheet spring 10 24 12 SCREW slotted head 10 32 x 3 4 in 19 mm 12 AIR REGULATOR 1 2 npt f inlet and outlet 1 4 npt f gauge ports 0 125 psi 0 8 bar range See manual 307204 1 SWIVEL
15. 14 15 If removing the pump only remove it from the manifold 32 If the primary pump needs repair follow the instructions in the separate pump manual If removing the lower bearing 14d and pin 35d tilt the primary pump 123 forward until it rests on the floor Then follow steps 13 to 15 Loosen the lower rod end locknut 3 and unscrew the pump manifold 32 to remove the primary pump 123 Loosen the two setscrews 17b The setscrews must be backed out far enough to clear the coun tersinks of the support pin 35d Remove the pin 35d and save the two nylon spacers 27d and the bearing 144 02375A Service Replacing the Primary Pump and or Bearing and Pins NOTE Refer to Fig 17 for Steps 1 to 9 except where noted 1 Screw the displacement pump 123 into the inlet manifold 32 so the outlet is facing the back 2 Screw the connecting rod 121 onto the primary displacement pump until the cotter pin holes line up Install the cotter pin 102d if the pump has one if not bottom out the connecting rod on the displacement pump 3 Pull the connecting rod upward until the displace ment pump stops 4 Screw the air motor 118 onto the connecting rod until the cotter pin holes line up Install the cotter pin 102c 5 Rotate the air motor until the air inlet port is on the same side as the air inlet manifold 37 6 Screw the three tie rods 116
16. 17 1 4 1 to 6 7 1 1 10 to 0 70 1400 to 2200 4 2 to 2 6 9 7 to 15 97 to 152 222012 222019 1 9 1 to 9 0 1 1 10 to 0 70 1600 to 2300 4 2 to 2 6 11 to 16 110 to 159 TMaximum to minimum ranges NOTE Output pressure decreases as volume output increases tBased on pump speed of 40 cycles per minute using No 10 oil test media 36 309024 xo KO o Co 119 Ge 02380B All President Options Ref No 102 103 104 106 107 108 110 111 115 116 117 118 119 120 121 Part No 100103 101566 102814 100139 155541 156823 158962 161037 177088 177111 177112 177471 177113 177114 177115 207352 108233 215626 215691 215692 215693 Description PIN cotter LOCKNUT sst 3 8 16 GAUGE pressure 5000 psi 34 MPa 350 bar 1 4 npt m PLUG pipe 1 8 npt UNION swivel 90 1 4 npt m x 1 4 npsm f UNION 1 4 pt m x 1 4 npt f ELBOW street 1 4 npt f x 1 8 npt m UNION swivel 1 2 npt f x 3 8 npsm f UNION swivel 3 8 npt f x 3 8 npsm f TIE ROD 16 407 mm shoulder to shoulder TIE ROD 15 2 385 mm shoulder to shoulder TIE ROD 16 9 429 mm shoulder to shoulder CONNECTING ROD 2 62 66 5 mm long CONNECTING ROD 2 5 64 4 mm long CONNECTING ROD 3 39 88 1 mm long MOTOR President SAMPLING VALVE needle MANIFOLD4 CONNECTING ROD 13 5 342 mm CONNECTING R
17. 2 5 bar 1 25 MPa 180 psi Bulldog 347 bar 34 7 MPa 4950 psi 6 3 bar 0 63 MPa 90 psi Air Pressure of Sound Tests Sound Pressure Sound Power Pump Model 25 cycles min Level Level President 12 5 bar 1 25 MPa 98 dBa 113 dBa 180 psi Monark 12 5 bar 1 25 MPa 96 dBa 112 dBa 180 psi Bulldog 7 bar 0 7 MPa 94 dBa 109 dBa 100 psi A Sound pressure was measured in accordance with Cagi Pneurop 1969 Sound power was measured in accordance with ISO 3744 1981 309024 39 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 by an authorized Graco distributor 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 accor dance 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 sub stitution of non Graco component parts Nor shall Graco be liable for malfunction damage or
18. 4 Fig 3 2 Airand fluid hoses use only electrically conductive hoses Air compressor follow manufacturer s recommen dations Spray gun dispense valve ground through connec tion to a properly grounded fluid hose and pump Fluid supply container follow your local code Object being sprayed follow your local code Solvent pails used when flushing follow your local code Use only metal pails which are conductive placed on a grounded surface Do not place the pail on a nonconductive surface such as paper or cardboard which interrupts the grounding continu ity To maintain grounding continuity when flushing or relieving pressure hold a metal part of the spray gun dispense valve firmly to the side of a grounded metal pail then trigger the gun valve 309024 9 Ratio Adjustment Understanding the terms used with the Variable Ratio Hydra Cat VRHC System how it functions and how to find and set the correct ratio s for your applica tion is the key to easier more versatile operation of your proportioning system Be sure to read and understand the following informa tion before operating the equipment Terms The ratio refers to the simultaneous output of a certain volume of fluid by the primary and secondary pumps The primary pump 123 is directly under the motor it usually pumps the base fluid Fig 4 10 309024 The secondary pump 124 is on the opposite end of
19. OD 11 8 300 mm CONNECTING ROD 12 7 821 mm Qty Options 3 Parts A04 A06 All Others All All All All All All A04 A06 All A09 A12 A14 D02 F06 686632 A04 A06 A09 A12 A14 D02 F06 686632 A04 A06 All All All A06 A09 A12 A14 D02 F06 686632 A04 Ref No 122 123 124 125 126 127 128 129 130 131 132 133 134 135 Part No 215925 215932 215930 222012 222015 222017 222017 222015 215932 215930 222012 222015 222017 222019 222019 215690 164417 155494 158212 162449 237063 159239 158683 113187 190738 237569 Description HOUSING VRHC PRIM DISPL PUMP PRIM DISPL PUMP PRIM DISPL PUMP PRIM DISPL PUMP PRIM DISPL PUMP PRIM DISPL PUMP PRIM DISPL PUMP SEC DISPL PUMP SEC DISPL PUMP SEC DISPL PUMP SEC DISPL PUMP SEC DISPL PUMP SEC DISPL PUMP SEC DISPL PUMP MOUNTING PLATE LOCKNUT UNION 3 8 npt mxf BUSHING 1 2 npt m x 3 8 npt f NIPPLE 1 2 x 1 4 npt VALVE relief 2900 to 3600 psi 20 to 24 8 MPa 200 to 248 bar NIPPLE 3 8 x 1 2 npt ELBOW 90 steel CONNECTOR female tube TUBE nylon WIRE ground 1See manual 307430 for parts 2See manual 307431 for parts 3See manual 307944 for parts 4See manual 307400 for parts 5See manual 306982 for parts Qty Options i i i i i i i i i i i i i i ot n
20. OR Monark See parts in manual 308043 Ref No 119 120 121 122 123 124 125 126 127 128 129 130 Part No 108233 215626 215693 215925 215932 222015 215932 222019 162449 237060 159239 158683 113187 190738 Description Qty SAMPLE VALVE needle 2 MANIFOLD See parts in manual 307400 CONNECTING ROD 12 67 inch 321 8 mm UNIT FRAME long see parts on pages 32 to 35 PRIMARY DISPL PUMP 1 See parts in manual 307430 SECONDARY DISPL PUMP 1 Used in MO1 Option See parts in manual 307431 SECONDARY DISPL PUMP 1 Used in A01 Option See parts in manual 307430 SECONDARY DISPL PUMP 1 Used in Q01 Option See parts in manual 307431 NIPPLE 1 2 x 1 4 RELIEF VALVE 475 33 to 575 400 psi bar working pressure NIPPLE 3 8 x 1 2 ELBOW 90 1 2 x 1 2 CONNECTOR female TUBE nylon tube cl c 309024 31 Unit Frame All Options AX Torque to 35 in Ib 4 N m LN Torque to 60 ft lb 81 N m 32 309024 Unit Frame All Options Ref No Part No 2 100071 3 100155 5 100509 9 101747 12 103836 14 105751 15 105752 16 100060 17 105762 25 159463 26 177042 27 177086 28 177089 30 177099 31 177100 Description LOCKNUT hex 3 4 16 NUT 5 8 18 PLUG pipe 1 4 npt PLUG bottom 1 4 npt m SCREW slotted head 10 32 x 3 4 in 19 mm BEARING rod end BEARING rod end CAPSCREW hex head 1 2 13 x
21. aster air valve required in your system 3 Unlock the gun valve trigger safety 4 Hold a metal part of the gun valve firmly to the side of a grounded metal pail and trigger the gun valve to relieve pressure 5 Lock the gun valve trigger safety 6 Open the drain valve required in your system having a container ready to catch the drainage 7 Leave the drain valve open until you are ready to spray dispense again If you suspect that the spray tip nozzle or hose is completely clogged or that pressure has not been fully relieved after following the steps above very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually then loosen completely Now clear the tip nozzle or hose 309024 15 Operation The pumps mixer manifold and other components were tested with lightweight oil at the factory Before operating the pump thoroughly flush the VRHC to prevent contamination of the fluids System Flushing NOTE Flush the mixer hose and gun valve often enough to prevent fluid from reacting or curing in them Contact your fluid manufacturer for the effective pot life of the fluid you are using 1 Put the pump intake hoses of the feed pumps into 5 gallon 20 liter containers of compatible solvent Refer to the fluid manufacturer s recommenda tions 2 Start the pump as explained below 3 Do not install the spray tip nozzle yet Hold a metal part of the gun valve firmly to
22. bearings 15 5 Slide the support pin with the countersinks up through the lever arm and bearings Torque the two setscrews 17 to 35 in lb 4 N m NOTE If no drag is felt while turning the setscrews replace them Service AN Torque to 35 in Ib 4 N m LN Torque to 60 ft Ib 81 N m 02371A 309024 29 Parts For Monark Options A01 M01 and Q01 5 130 125 YT 128 ee 129 117 02434A 30 309024 Parts For Monark Options A01 M01 and Q01 Ref No 102 103 104 105 106 107 108 109 110 111 114 115 116 117 118 Part No 100103 101566 104088 100139 105770 155494 155541 156823 158962 161037 172446 177088 177109 177114 177113 205997 Description Qty PIN cotter LOCKNUT 3 8 16 RIVET PLUG pipe 1 8 npt FLUID PRESSURE GAUGE 1000 psi 70 bar 1 4 npt m UNION 3 8 npt m x 3 8 npt f SWIVEL UNION 90 1 4 npt m x 1 4 npsm f UNION 1 4 npt m x f ELBOW street 1 4 npt f x 1 8 npt m SWIVEL UNION 1 2 npt m x 3 8 npsm f PLATE designation SWIVEL UNION 3 8 npt f x 3 8 npsm f two 1 8 npt f ports TIE ROD 15 81 inch 401 6 mm shoulder to shoulder CONNECTING ROD 2 535 inch 64 4 mm long used in A01 Option CONNECTING ROD 2 62 inch 66 5 mm long used in MOI and Q01 Options AIR MOT
23. cycles min lubricate at the points shown in Fig 9 once every five days Service instructions are in the manuals for the sepa rate components See the chart on page 18 20 309024 Air Lubrication Air Operated Motors Only If your air supply is very dry install air line lubricators between the air regulators and pumps for automatic air motor lubrication See Accessories in Configurator Product Order Form 309025 for a lubricator Lubricate periodically with Graco Gear Reducer Oil AN Fig 9 02371A Detecting Bearing and Pin Wear Audio Detection When a bearing fails it makes a knocking noise each time the pump changes stroke Shut off the system immediately to avoid serious damage Replace the bearing s Visual Detection Check the movement of the lever arm 49 by watching it through the opening in the safety panel 39 If it bounces shut off the system immediately to avoid serious damage Replace the bearing pin Service Removing the Lever Arm from the VRHC 11 Remove the punch and lift the lever arm 49 off Frame the VRHC frame A WARNING 12 Loosen the two pivot bearing locknuts 2 and turn the bearings 15 out of the housing 122 The bearings should be only hand tight If they are tighter use a wrench on the flats of the bearing 15 to unscrew the bearing from the frame To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow t
24. e Be sure that all dispensing equipment and accessories are rated to withstand the maximum working pres sure of your pump Do not exceed the maximum working pressure of the lowest rated system component Never operate the pump without the automatic pressure relief valves and drainage kits installed These valves relieve fluid pressure through a drain port at the bottom of the valve if the displace ment pump pressure exceeds the working pressure Never exceed the recommended working pressure or the maximum air inlet pressure stated on your pump or in the Configurator Product Order Form 309025 Do not lift pressurized equipment Use only Graco approved hoses Do not remove hose spring guards which help protect the hose from rupture caused by kinks or bends near the couplings Route the hoses away from the traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F 40 Do not use the hoses to pull the equipment Use fluids and solvents that are compatible with the equipment wetted parts See the Technical Data section of all the equipment manuals Read the fluid and solvent manufacturer s warnings Comply with all applicable local state and national fire electrical and other safety regulations 309024 3 A WARNING SKIN INJECTION HAZARD Spray from the spray gun hose leaks or ruptured components can inject fluid into your body and ca
25. er to the base before proportioning with the VRHC System determine the ratio of the base reducer mixture to the catalyst in order to set the secondary pump at the correct position In this example the instructions on the can say Mix 5 parts base to 1 part catalyst Then reduce 3 parts of this mixture to 1 part reducer 1 Add the parts of the base and catalyst to find the parts mixture 5 parts base 1 parts catalyst 6 parts mixture 2 The next statement on the can says Reduce 3 parts of the mixture So divide the parts of the mixture by 3 to find the parts reducer 6 parts mixture 3 part catalyst 2 parts reducer 3 To determine the ratio of the secondary pump add the appropriate parts of base and reducer to find the parts combined base reducer 5 parts base 2 parts reducer 7 parts combined base reducer to 1 part catalyst Result The ratio of the secondary pump is 7 1 309024 11 Set the Ratio Fig 5 shows the relationship between the primary pump and the secondary pump To set the secondary pump on a standard VRHC System with only two pumps refer to Setting the Secondary Pump s on page 14 To set the secondary pump on a non standard VRHC System or for an additional secondary pump refer to Calculate the Ratio Setting on page 13 NOTE The 91 index setting provides equal primary and secondary pump stroke lengths 100 is 1 1 times the primary pump stroke allowing adjustability
26. essful troubleshooting is to be sure to isolate the problem For example the secondary pump pressure as read on the gauge is low and sluggish during pump changeover The most likely problem is a binding primary pump A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 15 To isolate the pump 1 Relieve the pressure 2 Disconnect the index clamp 30 from the secondary pump and lean the pump out of the way of the lever arm 49 Now you can verify the operation of the primary pump alone 3 Use the sampling valves 119 at the mixer manifold 120 a Check the outlet ratio for the primary side b With the sampling valves closed check for pump stalling on both the up and down strokes c Check for rapid gauge response during pump changeover 4 When the operation of the primary side has been verified reconnect the lever arm 49 to the secondary pump Let the primary pump run freely in a pail of fluid and repeat the checks in Step 3 on the secondary side 18 309024 A WARNING Use very low air pressure to the air motor when making these checks This system can produce very high fluid pressure which can cause serious injury including injection splashing in the eyes or on the skin and injury from moving parts Follow the Pressure Relief Procedure on page 15 A WARNING To reduce the risk of injur
27. essure Relief Procedure on page 15 2 Relieve the pressure 3 Remove the safety panels 39 40 Disconnect the inlet and outlet hoses on the primary displacement pump 123 NOTE Refer to Fig 15 for Steps 4 to 6 4 Remove the three tie rod locknuts 103 and push up on the air motor 118 until the tie rods 116 clear the mounting holes of the displacement pump See Fig 15 5 Using a wrench on the flats of the tie rods 02375A unscrew them from the air motor base Fig 15 6 Remove the upper cotter pin 102c and unscrew the air motor from the connecting rod 121 Continued on page 26 309024 25 Service NOTE If only the motor needs repair follow the instructions in the appropriate manual NOTE Refer to Fig 16 for Steps 7 to 15 7 10 Remove the lower cotter pin 102d from the connecting rod 121 if the pump has one and loosen the two setscrews 59 The setscrews must be backed out far enough to clear the coun tersink of the bearing support pin 35c Hold the connecting rod 121 and gently tap out the support pin 35c with a hammer and punch Slowly pull the connecting rod 121 away from the lever arm 49 and tilt the pump 123 forward until it rests on the frame Save the two nylon spacers 27c Unscrew the connecting rod 121 from the displacement pump 123 If necessary replace the connecting rod Fig 16 26 309024 11 12 13
28. fold Grounded Fluid Hose 123 Air Motor Air Pressure Gauge 124 Secondary Proportioning Pump Slave 123 L J KEY Pressure Reducing Valve Accumulator Pump Ground Wire required A Hydraulic Pump K Feed Pumps B Mounting Stand P Hydraulic Supply Line Shutoff Valve C Hydraulic Supply Line R Hydraulic Return Line Shutoff Valve D Hydraulic Return Line S Hydraulic Return Line Filter E Drain Line from pressure reducing valve U Hydraulic Power Supply F Pressure Gauge V Fluid Hose G Flow Control Valve W Fluid Supply Line H Y J eui Mea TRITT Uf 000 J J ANE C Lara 3t Pi h FLED Fig 2 309024 7 Installation NOTE Reference numbers and letters in the text refer to Figures 1 to 18 Location Sit the proportioner on a flat floor positioner Connect the Solvent Flush Supply Line Remove the
29. handle Solvent Catalyst Solvent ie valve shown m closed Handle Down Mixer Open 02370 Operation NOTE To open the mixer manifold 120 put the handle in the down position To close the mixer manifold put the handle in the up position See Fig 7 on page 16 Standard Operating Flushing 1 Use the solvent valves to flush contaminants and mixed fluids from the mixer manifold hose and gun valve Follow the procedure below a Start the solvent pump Close the mixer manifold b Open one of the solvent valves EE c Trigger the gun valve into the metal pail until the solvent valve is thoroughly flushed Release the trigger d Close the open solvent valve Open the other solvent valve Repeat step c e With both solvent valves open flush until all contaminants and fluids are removed Release the trigger 2 To flush the sampling valves 119 place a grounded metal pail under them Turn the valve handle to the open position Flush until all contami nants and fluids are removed Close the sampling valves and solvent valves The solvent valves should be finger tight only but must be tight enough to prevent solvent from mixing with the fluid during operation 3 Trigger the gun valve to relieve pressure Checking the Ratio 1 Open the mixer manifold 120 2 Set the operating pressure After determining the operating pressure release the gun valve trigger and lock the trigger safety
30. he Pressure Relief Procedure on page 15 1 Flush the entire system with a solvent which is compatible with the fluid being pumped Discon nect the air line and relieve the pressure 2 Remove the safety panels 38 39 40 See Fig 10 3 Loosen the two setscrews 59 holding the primary lt displacement pump pin 35c in the lever arm 49 See Fig 11 The setscrews must be backed out far enough to clear the countersinks of the pin Tap the pump pin out of the lever arm and bearing i 4 Slide the primary pump out of the lever arm 49 so amp Q slot and save the two nylon spacers 27c A 5 Slowly lower the pump to the floor until it supports ERN x NK itself with the lower bearing 14d See Fig 17 on diee page 27 S 42 1 i 38 6 Push down on the secondary displacement pump 1 are end of the lever arm 49 at point JJ until it is at the bottom of the stroke See Fig 11 Fig 10 7 Remove the two top capscrews 16a from the index clamp 30 8 Raise the lever arm 49 slowly Lower the secondary pump to the floor until it supports itself with the lower bearing 9 Loosen the two setscrews 17 located above the ends of the frame pin 33 The setscrews must be turned out far enough to clear the countersinks of the pin 10 Using a long punch and hammer gently drive the frame pin 33 out from one end until it can be pulled out A CAUTION Do not drop the pin dents will
31. he secondary pump The basic proportioner includes an air motor lower displacement pumps air controls fluid inlet hardware fluid outlet hoses manifold blocks and relief valve Additional proportioner accessories are selectable to complete the proportioner pump see Configurator Product Order Form 309025 309024 5 Typical Installation About Typical Installations The typical installations shown below and on page 7 are only guidelines to setting up a complete VRHC system For clarity various components are shown in the correct order but may not be shown in the exact position of the installed system For assistance in designing your system contact your nearest Graco representative NOTE When pressure feeding the proportioning pump mount fluid pressure gauges J at the propor tioning pump inlets to monitor proper adjustment of the feed pump pressures Never exceed 400 psi on the inbound fluid pressure and never exceed 25 of the Hydra Cat pump outbound fluid pressure on the feed supply Airless Spray Dispensing System for Light Viscosity Fluids m lt Air Supply Base Supply Catalyst Supply Base Supply Pump Air Shutoff Valve Catalyst Supply Pump Air Line Filter TACIOMMA Fig 1 6 309024 cO x c c Hmu Static Mixer 13 Air Regulator Primary Pump Inlet 45 Bleed type Master Air Valve Secondary Pump Inlet 46 Pressure Relief Valve Solvent Pump 104 Pressure Gauge Airless Spray Gun 120 Mixer Mani
32. he support pin 34a b Place the support 31a in a vise Unscrew the connecting rod 117 from the bearing 14a The connecting rod and bearing are sealed with thread sealant and may be difficult to unscrew c Remove the support 31a from the vise Gently tap the support pin 34a out with a hammer and punch d Replace the support pin and bearing 10 If removing the lower bearing 14b and support pin 34b a Remove one of the lower clamps 28 and capscrews 16b b Loosen the locknut 3 and screw the pump manifold 32 off the bearing 14b to remove the secondary displacement pump 124 c Remove the remaining clamp 28 and cap screw 16b from the lower support 31b d Fig 14 Raise the VRHC lower frame 50 and remove the support 31b Gently tap the support pin 34b out with a hammer and punch Replace the pin and bearing 02374 309024 23 Service Replacing the Secondary Pump and or the d Screw the secondary displacement Bearings and Pins pump 124 and manifold 32 onto the bearing 14b until it bottoms out Be sure it is NOTE Refer to Fig 14 for Steps 1 to 3 not resting against the locknut 3 1 If only the secondary pump is being replaced e Align and loosely install the two clamps 28 and capscrews 16b a Screw the secondary pump 124 into the inlet manifold 32 The manifold must face the end 3 Ifreplacing the upper bearing 14a and support of
33. ing 14b and support 14a Me Connie gang Tod andthe bearing can pin 34b be disassembled and then reused one time before needing replacement Be sure to seal the connecting rod and the bearing with thread sealant such as Loctite No 27105 or the equivalent Apply 3 drops of the sealant to the threads of the bearing a Place a generous amount of Graco Gear Reducer Oil 43 on the inside of the lower bearing 14b and the surface of the support pin 34b e Screw the connecting rod 117 onto the b Screw the locknut 3 onto the bearing 14b pump 124 until the cotter pin holes line up if threads until the locknut bottoms out the displacement pump has them Install the cotter pin 102 and tighten the connecting rod c Slide the bearing into the slot in the against the piston shoulder of the displace support 31b Insert the pin 34b into place ment rod with the countersinks under the setscrew 17 holes Tighten the setscrews to 35 in Ib 4 f Follow steps 1 c to 1 f at left N m These are 10 32 self locking setscrews If no drag is felt while turning replace the g Tighten the capscrews 16b at the bottom of setscrew the secondary displacement pump 124 24 309024 Service Removing the Primary Pump and or the Lower Bearing and Pin 1 Flush the entire system with a compatible solvent A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pr
34. ing or amputating a hand fingers or other body parts never place your hands or any part of your body or any tools inside the safety panel at any time for any reason while the unit is operating Refer to the manuals listed below to repair the VRHC components Component Ret No Manual No Problem Troubleshooting Cause Solution System won t run or stops while running 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 Air motor worn or damaged Service air motor see manual 306982 Displacement pump stuck Service displacement pump See manuals listed in the chart on Replace fluid hose page 18 Fluids not mixing properly Clogged filter in fluid line Clean replace element if neces sary Manifold problems Refer to manual 307400 Check ratio Clogged fluid hose Replace fluid hose System speeds up or runs erratically Fluid containers are empty Check often keep filled Displacement pump parts worn or damaged Service displacement pump See Check replace pump manuals listed in the chart below Squeaking or knocking noise is heard Bearing s dry or worn Lubricate replace bearing s if necessary Pump bottoming out System stops running on
35. into the air motor base and torque to 35 50 ft lb 47 68 N m NOTE One of the tie rods will run through the lever arm slot Fia_ 17 7 Push down the air motor and place the tie rods into the displacement pump tie plate Tighten the tie rod locknuts 103 8 To install the support pin 35c into the upper bearing a Remove the two capscrews 16a from the support 31a on the secondary pump 124 b Move the lever arm 49 until you can place the nylon spacers 27c and support pin 35c in line with the bearing in the connecting rod 121 c Lubricate the support pin with Gear Reducer Oil 43 and tap it into the upper bearing with the countersinks facing up A CAUTION Do not force the pin into place Check for burrs on the pin or in the VRHC frame if the pin does not slide into place Sand with 500 grit sandpaper between the countersinks d Torque the two setscrews 59 to 35 in Ib 4 N m See Fig 18 on page 29 e Move the lever arm 49 back into place and reinstall the two capscrews 16a onto the support 31a of the secondary pump AN Torque to 60 ft Ib 81 N m Torque to 35 in Ib 4 N m 309024 27 02375A Service 9 If replacing the lower bearing 14d and pin 35d a Thread the locknut 3 all the way onto the bearing b Screw the inlet manifold 32 onto the bearing twelve turns and tighten the locknut up to the inlet manifold Torque to 60 ft
36. ntire system with a compatible solvent A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 15 2 Relieve the pressure 3 Remove the safety panel 39 See Fig 13 Disconnect the inlet and outlet fluid hoses of the secondary displacement pump 124 02366A Fig 13 Continued on page 23 Service NOTE Refer to Fig 14 for steps 4 to 10 4 Push down on the lever arm 49 until the wrench flats KK on the secondary pump 124 are just above the wet cup LL Remove the ratio index clamp capscrews 16a and the index clamp 30 NOTE Some fluid will drip from the pump when you are removing the ratio index clamp 5 Raise the lever arm 49 off the pivot pin support 31a 6 Remove the connecting rod cotter pin 102 if the pump has one Unscrew the connecting rod assembly 117 14a 34a 31a in one piece from the pump 7 If you are removing only the pump remove it from the inlet manifold 32 If the secondary pump s need repair follow the instructions in its manual 8 If you are removing the bearings and pins tilt the secondary pump 124 forward until it rests on the floor Then follow Steps 9 and or 10 9 If you are removing the upper bearing 14a and support pin a Loosen the two setscrews 17a Back out the setscrews far enough to clear the countersinks of t
37. ranty 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 reconnais sent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Information TO PLACE AN ORDER contact your Graco distributor or call one of the following numbers to identify the dis
38. rdous fluid in an approved container Dispose of hazardous fluid according to all local state and national guidelines Always wear protective eyewear gloves clothing and respirator as recommended by the fluid and solvent manufacturer Avoid exposure to heated material fumes Provide adequate ventilation Graco does not manufacture or supply any of the reactive chemical components that may be used in this equipment and is not responsible for their effects Graco assumes no responsibility for loss damage expense or claims for personal injury or property damage direct or conse quential arising from the use of such chemical components System Information This manual describes pumps designed to be part of a Variable Ratio Hydra Cat Pump VRHC dispensing system The VRHC proportions mixes and dispenses two component fluid materials by powering two positive displacement pump lowers from a common air motor This assures that the stroke rate and stroke length of all pump lowers are proportional as set providing constant proportioning The mix ratio is determined by the movement of the outboard slave pump along the arm of the machine This movement changes the stroke of the slave cylinder and along with its volumet ric output relationship to the master cylinder deter mines the output volumetric ratio The volumetric ratio is expressed as the proportion of the volume of fluid of the primary pump compared to the volume of t
39. rmation 060 cece eee eee 40 Related Manuals Manual President Air Motors Monark Air Motors Bulldog Air Motors Viscount Displacement Pump Displacement Pumps Displacement Pumps Displacement Pumps Configurator Product Order Form Displacement Pumps Displacement Pumps 2 309024 No 306982 307043 307049 307654 307430 307431 307944 684004 309025 306936 307862 Warnings Warning Symbol Caution Symbol This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions or destruction of equipment if you do not follow the instructions A WARNING S4 EQUIPMENT MISUSE HAZARD e EX Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result INSTRUCTIONS in serious injury H Mad This equipment is for professional use only Read all instruction manuals warnings tags and labels before operating the equipment Use the equipment only for its intended purpose If you are uncertain about usage call your Graco distributor Do not alter or modify this equipment Use only genuine Graco parts and accessories Check the equipment daily Repair or replace worn or damaged parts immediately See Configurator Product Order Form 309025 for important pressure rating information The maximum working pressure of each model is also shown on the pump identification plat
40. se a hazardous condition and result in fire explosion or electrostatic shock and other serious injury e Ground the equipment the object being dispensed and all other electrically conductive objects in the dispense area Proper grounding dissipates static electricity generated in the equipment Refer to System Grounding on page 9 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or material Do not use the heater with flammable liquids such as those having flash points below 200 F 93 C Extinguish all open flames or pilot lights in the dispense area Do not turn on or off any light switch in the dispense area Do not use this equipment with flammable liquids Keep the dispense area free of debris including solvent rags and gasoline Do not smoke in the dispense area Do not operate a gasoline engine within the spray area If there is any static sparking or you feel an electric shock while using the equipment stop dis pensing immediately Do not use the equipment until you have identified and corrected the problem 4 309024 A WARNING MOVING PARTS HAZARD Moving parts can pinch fingers e Keep clear of all moving parts when starting or operating the equipment 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 Know the specific hazards of the fluid you are using Store haza
41. the compressed air supply Downstream from the air filter the air regulator 13 and the bleed type master air valve 45 install an air line lubricator to provide automatic lubrication to the motor A WARNING The bleed type master air valve 45 is required in your system to relieve air trapped between this valve and the pump after the pump is shut off Trapped air can cause the pump to cycle unexpect edly resulting in serious injury including amputa tion Connect the Air Supply Line Connect a grounded air supply hose to the 1 2 npt f port of the air manifold 37 Open the bleed type master air valve 45 and using the pressure gauge 8 set the air regulator 13 to the desired pressure See Figure 1 and 2 Pressure Relief Valve Before operating the VRHC make sure all compo nents have rated working pressures of 3000 psi 21 MPa 207 bar or greater For more information about the pressure relief valve see Instruction Manual 308547 Installation Grounding A 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 4 Pump use the ground wire and clamp supplied See Fig 3 Loosen the grounding lug locknut W and washer X Insert one end of the ground wire Y into the slot in lug Z and tighten the locknut securely Connect the other end of the wire to a true earth ground Ww 086
42. the lever arm 49 It usually pumps the catalyst One or two secondary pumps may be used one for pump ing catalyst and the other for reducer injection If two secondary pumps are used then two ratios exist The ratio index clamp 30 is used to adjust the ratio of the secondary pump s There are three main points to remember when applying the use of ratios 1 Determine the ratio required 2 Calculate the ratio setting 3 Setthe ratio on the VRHC System 124 KEY 38 DD Manifold Lever EE Solvent Valves 02366B Determining the Ratio Determine your system conditions If these are your conditions one primary pump one secondary pump fluids are ready to spray viscosity set the ratio as explained under Setting the Secondary Pump s on page 14 If these are your conditions one primary pump and one secondary pump fluids are NOT ready to spray viscosity the ratio must be determined after the reducer is added to the base as instructed in Procedure 1 NOTE The addition of the reducer in the base causes changes to the ratio To prevent reducer evaporation store the base in closed containers NOTE Some reducers have very little ability to lubri cate and may cause seals to dry out To prolong seal life be sure your pump seals are compatible with the base s reducer Contact your Graco distributor for the correct seals to use Procedure 1 Base Is Pre reduced When adding reduc
43. the side of a grounded metal pail Using the lowest possible fluid pressure trigger the gun valve into the pail 4 When clean solvent comes from the gun valve release the trigger and carefully check all connec tions in the system for leaks 5 Take the hoses out of the solvent and trigger the gun valve until all solvent has been pumped out of the hoses Solvent Handle Up Mixer Closed Catalyst Solvent valve shown open Solvent Out Fig 7 16 309024 Starting the Pump NOTE To open the mixer manifold 120 put the handle in the down position To close the mixer manifold put the handle in the up position See Fig 7 A CAUTION Never exceed 25 of the normal proportioner output pressure with the feed system 1 Start feed pump supplies and ensure fluid pres sure is at least 25 psi at each pump outlet 2 Close the bleed type master air valve Turn the air regulator knob all the way out counterclockwise 3 Turn on the main air supply 4 Open the mixer manifold handle trigger the gun valve slowly open the bleed type master air valve and turn the air regulator knob clockwise until the pump starts 5 Allow the pump to cycle slowly until all the air is pushed out of the lines Release the trigger the pump will stall against the pressure 6 The manifold handle controls fluid flow When the manifold is open base and catalyst are supplied to the gun valve To stop the flow close the
44. tributor 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 MM 309024 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com PRINTED IN USA 309024 July 1999 Rev 02 2006 40 309024
45. use extremely serious injury including the need for amputation Splashing fluid in the eyes or on the skin can also cause serious injury Fluid injected into the skin might look like just a cut but it is a serious injury Get immediate medi cal surgical treatment Do not point the gun valve at anyone or at any part of the body Do not put your hand or fingers over the spray tip nozzle Do not stop or deflect fluid leaks with your hand body glove or rag Do not blow back fluid this is not an air spray system Check the gun diffuser operation weekly Refer to the gun manual Always have the trigger guard on the gun when dispensing Be sure the gun valve trigger safety operates before dispensing Lock the gun valve trigger safety when you stop dispensing Follow the Pressure Relief Procedure on page 15 whenever you are instructed to relieve pres sure stop spraying dispensing clean check or service the equipment and install or clean the spray tip nozzle Tighten all fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn damaged or loose parts immediately Do not repair high pressure couplings you must replace the entire hose Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Improper grounding poor air ventilation open flames or sparks can cau
46. ve area by the ratio required 0 278 catalyst pump s effective area X 5 ratio required 1 39 answerb a Divide answer a by answer b to determine the index setting 42 77 answera T 1 39 answerb 30 8 catalyst pump index setting 2 To make sure the index setting does not exceed the secondary pump s maximum stroke length a Multiply the index setting by 0 044 a constant number 30 8 catalyst pump setting X 0 044 constant 1 355 catalyst pump stroke length a See the Pump Specifications Chart on page 12 for the pumps maximum stroke length Do not use an index setting which will exceed the maximum stroke length for your pump model To make sure the index setting does not go below the secondary pump minimum ratio setting refer to 309025 Configured Product Order Form Do not use a ratio higher than that specified in the maxi mum set position mix ratio column for your sys tem The number 1 355 from step 2 a does not exceed the pump maximum stroke nor does it go below the minimum ratio setting so set the cata lyst pump at the 30 8 index setting NOTE The ratio index is only a reference point and ratio checks must be performed to qualify the exact ratio set desired 309024 13 Setting the Secondary Pump s The numbers of the pump settings calculated from the procedures in the section Calculate the Ratio Setting correspond to the scale numbers on the lever arm 49 of the VRHC See Fig 6 A WARNING
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