Graco 308224H User Manual

Instructions – Parts List

PRESIDENT HYDRA-CATr FIXED RATIO

308224H

Proportioning Pumps

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 certified and approved see pages 6 and 7.

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 26. . . . . . . . . . . . . . . . . . . . . .

Parts – Bare, Three Pumps 28. . . . . . . . . . . . . . . . . . . . .

Parts – Wall Mount, Two Pumps 30. . . . . . . . . . . . . . . . .

Parts – Wall Mount, Three Pumps 32. . . . . . . . . . . . . . .

Parts – Stand Mount, Two Pumps 34. . . . . . . . . . . . . . .

Parts – Stand Mount, Three Pumps 36. . . . . . . . . . . . . .

Accessories 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Hole Layout for Air Motor 42. . . . . . . . . . . . . .

Technical Data 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 44. . . . . . . . . . . . . . . . . . . . . .

Graco Information 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.

3082242

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.

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.

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 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 Tech-

nical 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.

3082244

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 spray-

ing 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

Ratio

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

A B

Maximum Pump

Model No.

Mix Ratio

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** 231595** 1921 135 2300 159 19.21 1.0 3.8 1:1 231646** 2561 179 2900 200 25.61 0.75 2.8

Bare Wall Stand psi bar psi bar

Fluid Pressure

at 100 psi (7 bar) Air

Minimum

Component

Working Pressure

Normal

Pressure

Ratio

(Fluid to Air)

Nominal Flow

Volume

@ 40 cpm

gpm lpm

** CE approved and certified.

3082246

List of Models

Ratio

Models with Three Displacement Pumps

A B

Maximum Pump

Model No.

Mix Ratio

2:1 231657** 231607** 231632** 1280 88 1800 124 12.80 1.50 88 2:1 231658** 1707 118 1800 124 17.07 1.12 11 8 4:1 231663** 231613** 231638** 1024 71 1150 79 10.24 1.87 71

Bare Wall Stand psi bar psi bar

Fluid Pressure

at 100 psi (7 bar) Air

**CE approved and certified

Minimum

Component

Working Pressure

Normal

Pressure

Ratio

(Fluid to Air)

Nominal Flow

Volume

@ 40 cpm

gpm lpm

308224 7

Typical Installation

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 Bleed-type master

air valve B Air filter C Air lubricator D Pump runaway valve E Pump air regulator F Feed pump G Ground wire

H Proportioning pump J Fluid pressure gauge K Check valve L Automatic pressure relief

valve M Fluid filter N Mixer manifold

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.

P Fluid drain valve Q Fluid shutoff valve R Static mixer S Dispense valve T Fluid regulator U Solvent pump V Fluid strainer

See note above

Connect to drain bottle.

See Fig. 5, page 11

* Included with wall or stand models

Fig. 1

HJ*K*

HARD

RES

HARDENER RESIN

HARD

RES

02885

3082248

Typical Installation

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 Bleed-type master air valve B Air filter C Air lubricator D Pump runaway valve E Pump air regulator F Feed pump G Ground wire H Proportioning pump

J Fluid pressure gauge K Check valve L Automatic pressure

relief valve M Fluid filter N Mixer manifold P Fluid drain valve Q Fluid shutoff valve

R Static mixer S Dispense valve T Fluid regulator U Solvent pump V Fluid strainer W Fluid heater X Supply manifold

See note above

Connect to drain bottle.

See Fig. 5, page 11

* Included with wall or stand models

E A

Fig. 2

L* M

02886

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.

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.

2. Label all pumps, hoses, fluid regulators, etc. to indicate whether they are for the resin side or hardener side of the system.

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.

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.

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).

Fig. 3

30822410

Installation

Air Control Accessories

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.

Automatic Pressure Relief Valves

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.

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.

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.

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

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.

38a 38b

Fig. 4

38c

02887

Fig. 5

38f

38g

38h

02888A

308224 11

Installation

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.

Connect Fluid Supply Hoses

For Two Displacement Pump Models

1. Connect the resin supply hose (EE) to the 3/4 npt swivel inlet (37B) for the resin displacement pump. See Fig. 6.

2. Connect the hardener supply hose (DD) to the 3/4 npt swivel inlet (37A) for the hardener displacement pump. See Fig. 6.

For Three Displacement Pump Models

1. Connect the resin supply hose (EE) to the 3/4 npt swivel inlet (37B) for the resin displacement pumps. See Fig. 7.

2. Connect the hardener supply hose (DD) to the 3/4 npt swivel inlet (37) for the center (hardener) displacement pump. See Fig. 7.

37B

RES

HARD

37A

02889

Fig. 6

37B

RES

HARD

RES

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 informa- tion.

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.

Fig. 7

37A

02890

30822412

Installation – Optional Fluid Heaters

All Models

NOTE: For systems requiring one heater for each

fluid, see page 38 to order the heaters and required

201a

201b

201

202

plumbing (items 201 to 205).

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.

OUT

203

Fig. 8

WARNING

To reduce the risk of serious injury, follow the Pressure Relief Procedure on page 21 before installing the heaters.

02891A

RES

2. Connect a swivel union (202) to the outlet of each heater. See Fig. 8.

3. Connect a swivel union (203) to the inlet of each heater. See Fig. 8.

For Two Displacement Pump Models

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.

2. Install a new fluid hose (204B) between the hardener heater outlet (202B) and the hardener mixer manifold. See Fig. 8–9.

3. Repeat Steps 1 and 2 for the resin pump (the “A” side).

23 (N)

HARD

Fig. 9

202A

RE S

OUT

204A

204B

202B

RES HARD

HARD

RES

10B10A

HAR D

OUT

203B203A

02893

308224 13

Installation – Optional Fluid Heaters

23 (N)

205A

202A

RES

RES HARD

HEATE R

OUT

Fig. 10

For Three Displacement Pump Models

RES HARD

17A 17B

HARD

RES

HARD HEATE R

203B203A

204B

202B

OUT

02894

16A

NOTE: You must provide two hoses (FA, FB in Fig.10) and fittings to run from the heater outlets to the mixer manifold inlets.

NOTE: To accommodate two resin fluid hoses, the mixer manifold (23) must be disconnected from the bracket and mounted remotely.

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.

2. Connect a new hardener fluid hose (204B) between the union (17B) and the swivel (203B) at the heater inlet. See Fig. 10.

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).

17A

17B

16B

RES

HARD

(N) 23

02892A

Fig. 11

30822414

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