Graco 238890, 238892, 238894 User Manual

Instructions–Parts List

STAINLESS STEEL, WATERBASE-COMPATIBLE, HIGH PRESSURE

Fluid Pressure Regulators

For precise downstream pressure and flow control.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions. See page 2 for List of Models and Table of Contents.

308647P

Model 238890, 238892

(spring-operated)

U.S. Patent No. 4942899

06290

06288

Model 238894

(air-operated)

06540A

Table of Contents

List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts

238889, 238890, 238891, and 238892 14. . . . . . . . . .

238893, 238894, 248090, and 255072 16. . . . . . . . . .

244734 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Models

Spring-Operated Models

Part No. Description Range

238889 with EZ Flush gauge port plug Medium

238890 with fluid pressure gauge Medium

238891 with EZ Flush gauge port plug High

238892 with fluid pressure gauge High

Technical Data 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Performance Chart 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensional Drawings 23. . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 24. . . . . . . . . . . . . . . . . . . . . .

Graco Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Fluid Inlet Pressure

6000 psi (41 MPa, 414 bar)

Regulated Fluid Outlet Pressure

500–3000 psi (3.4–21 MPa, 34–207 bar)

3000–5000 psi (21–34 MPa, 207–345 bar)

Air-Operated Models

Part No. Description Range

238893

238894

244734

248090

255072

2 308647

with EZ Flush gauge port plug

with fluid pressure gauge

with EZ Flush gauge port plug

with fluid pressure gauge (LASD)

high resolution with fluid pressure gauge

Full

Maximum Inbound Air Pressure

100 psi (0.7 MPa, 7 bar)

Maximum Fluid Inlet Pressure

6000 psi (41 MPa, 414 bar)

Regulated Fluid Outlet Pressure

500–4000 psi (3.4–28 MPa, 34–276 bar)

500–2700 psi (3.4–19 MPa, 34–190 bar)

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death 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.

INSTRUCTIONS

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 only genuine Graco parts and accessories.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

D Do not kink or over bend the hose or use the hose to pull equipment.

D Do not exceed the maximum working pressure of the lowest rated component in your system. Do

not exceed 6000 psi (41 MPa, 414 bar) maximum fluid inlet pressure of the regulator or 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 Always wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and

solvent manufacturer.

D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

3308647

WARNING

SKIN INJECTION HAZARD

Spray from the gun, 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 might look like just a cut, but it is a serious injury. Get immediate

surgical treatment.

D Do not point the gun at anyone or at any part of the body.

D Do not put your hand or fingers over the spray gun tip or extruder gun tip.

D Do not stop or deflect leaks with your hand, body, glove or rag.

D Always have the tip guard and the trigger guard on the gun when spraying.

D Check the gun diffuser operation weekly. Refer to the gun manual.

D Be sure the gun trigger safety operates before spraying.

D Lock the gun trigger safety when you stop dispensing.

D Follow the Pressure Relief Procedure on page 7 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 or damaged parts immediately. Do not

repair high pressure couplings; you must replace the entire hose.

D Fluid hoses must have spring guards on both ends to help protect them from rupture caused by

kinks or bends near the couplings.

HALOGENATED HYDROCARBON HAZARD

Never use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents, or fluids containing such solvents in these regulators. In the unlikely event that there is a diaphragm failure and the vent hole in the aluminum spring cap is plugged, a serious chemical reaction could occur, with the possibility of explosion, which could cause death, serious injury, and/or substantial property damage.

Consult your fluid suppliers to ensure that the fluids used are compatible with aluminum parts.

TOXIC FLUID HAZARD

Graco does not manufacture or supply the reactive chemical components that may be used in this equipment and is not responsible for injury or property loss, damage, expense or claims (direct or consequential) that arise from the use of such chemical components.

4 308647

Notes

5308647

Installation

Multiple Circulating Spray Station

Key

A Air regulator B Bleed-type master air valve C Pump D Fluid filter and drain valve E Main fluid supply line F Gun fluid supply line G Fluid regulator

with fluid pressure gauge (H)

H Fluid pressure gauge J Air-assisted airless spray gun K Back pressure valve L Fluid return line M Main circulating line N Fluid supply container P Drain valve

WARNING

06461

Single Direct Spray Station

Do not use PTFE tape on pipe threads. Such use could cause a hazardous condition due to loss of grounding continuity. Also, if pieces of the tape break off, the function of the regulator could be affected.

Fig. 1

The installations shown in Fig. 1 are only a guide for selecting and installing a circulating or direct system; they are not actual system designs. Contact your Graco distributor for assistance in designing a system to suit your needs.

NOTE: Before you install the regulator, thoroughly flush the system to remove metal chips and other contaminants. A fluid filter (D) of 60-mesh or finer should always be installed upstream of the regulator.

Connections

Install the fluid regulator (G) in the spray gun fluid supply line (F), as shown in the typical installation drawings on this page. Connect only one spray gun or dispensing valve to each fluid regulator.

Apply pipe sealant to the male pipe threads, and connect the fluid supply line (F) to the fluid regulator’s 3/8 npt(f) inlet. Connect the line from the gun (J) to the fluid regulator’s 3/8 npt(f) outlet. Install the gauge or plug into the 1/4 npt(f) gauge port.

Make sure the direction of fluid flow agrees with the IN and OUT markings on the regulator body.

06462

Flush the System

The regulator was tested in lightweight oil. Flush the entire system with a solvent compatible with the fluid being dispensed. Then test the system.

Mounting Bracket

A Mounting Bracket is available for mounting the regulator. Order Part 222515 for the bracket and mounting hardware.

6 308647

Installation

Grounding the System

WARNING

FIRE AND EXPLOSION HAZARD

Before operating the fluid pressure regulator, ground the system as explained below.

Pump: Use a ground wire and clamp. Loosen the grounding lug locknut (W) and washer (X). Insert one end of a 1.5 mm@ (12 ga) minimum 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. Order Part 237569 Ground Wire and Clamp.

0864

Fig. 2

Air and fluid hoses: Use only electrically conductive hoses.

Heaters, if used: See the heater instruction manual.

Air compressor: Follow manufacturer’s

recommendations.

Spray gun: Ground through connection 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 continuity.

To maintain grounding continuity when flushing or relieving pressure, hold a metal part of the spray gun

firmly to the side of a grounded metal pail, then trigger the gun.

Pressure Relief Procedure

WARNING

SKIN 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 Are instructed to relieve the pressure D Stop spraying D Check or service any of the system equipment D Install or clean the spray tips

7308647

Operation

Adjusting the System Pressure

CAUTION

D The new system must be cleaned and tested

thoroughly before admitting fluid to the regulator to avoid contaminants clogging or damaging the regulator.

D Always use the lowest possible air and fluid

pressures for your application. High pressures can cause premature spray tip, regulator, and pump wear.

NOTES:

D The fluid pressure regulator controls pressure

downstream from its outlet.

D If you are using an accessory fluid pressure gauge

(H in Fig. 1), relieve the spray gun line pressure after you reduce the regulator pressure to ensure a correct gauge reading.

2. Adjust the pump air pressure and fluid regulator for the desired spray pattern. Use the lowest possible air and fluid pressures for your application. For optimum performance, the inbound fluid pressure should be at least 500 psi (3.4 MPa, 34 bar) above the regulated fluid pressure.

NOTE: Do not exceed a 2000 psi (14 MPa, 138 bar) pressure drop between the regulator inlet and outlet. Excessive pressure drop will cause premature regulator component wear.

For example: With 3500 psi (24.5 MPa, 245 bar) to the regulator, the minimum regulated outlet pressure would be 1500 psi (10.5 MPa, 105 bar).

3. In a circulating system, also adjust the back pressure valve (K).

4. Record all the settings for future reference.

Cleaning the Regulator

1. Make a note of the proper way to adjust pressure, from the following descriptions:

D On a spring-operated regulator, turn the

adjusting screw (10) counterclockwise to decrease pressure and clockwise to increase pressure to the spray gun or extruder gun.

D On an air-operated regulator, increase supply

air pressure to increase fluid pressure. Decrease supply air pressure to decrease fluid pressure. Supply air up to 100 psi (0.7 MPa, 7 bar). See the chart on page 20 for air versus fluid pressure.

NOTE: Air-operated regulator Models 238893 and 238894 are provided with an air supply regulator (31) to control the fluid set pressure. For increased sensitivity in pressure set point performance, an alternative air regulator, such as Part 206197, may be used. This alternative air regulator uses a sensitive diaphragm design to maintain a higher, more accurate air pressure setting.

Do not allow fluid to settle in the system.

Flush the regulator whenever the rest of the system is flushed (see page 9). Before you flush the system, follow the Pressure Relief Procedure on page 7, then completely decrease the regulated fluid pressure. See step 1 in Adjusting the System Pressure, at left.

Before you remove the regulator for thorough cleaning and inspection, follow the Pressure Relief Procedure on page 7. Then remove the regulator, clean it, and inspect all parts.

8 308647

+ 16 hidden pages