Graco 309024C User Manual
Instructions
Parts
HYDRA-CATR VARIABLE RATIO
Proportioning Pumps
*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.
WARNING
309024C
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 reaction, 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.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 1999, Graco Inc. is registered to I.S. EN ISO 9001
Mounting as Shown:
Monark Air Motor and
Standard Manifold Shown
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Information 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratio Adjustment 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining the Ratio 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Set the Ratio 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculate the Ratio Setting 13. . . . . . . . . . . . . . . . . . . . .
Setting the Secondary Pump(s) 14. . . . . . . . . . . . . . . . .
Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Service Tools 20. . . . . . . . . . . . . . . . . . . . .
Bearing and Pump Lubrication 20. . . . . . . . . . . . . . .
Air Lubrication 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detecting Bearing and Pin Wear 20. . . . . . . . . . . . .
Removing the Lever Arm from
the VRHC Frame 21. . . . . . . . . . . . . . . . . . . . . . . .
Determining Which Pin
and/or Bearing is Worn 22. . . . . . . . . . . . . . . . . . .
Related Manuals
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 25. . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Primary Pump
and/or Bearing and Pins 27. . . . . . . . . . . . . . . . . .
Replacing the Lever Arm on the Frame 28. . . . . . .
Parts 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual No.
President Air Motors 306982
Monark Air Motors 307043
Bulldog Air Motors 307049
Viscount I 307654
Displacement Pump 307430
Displacement Pumps 307431
Displacement Pumps 307944
Displacement Pumps 684004
Configurator Product Order Form 309025
Displacement Pumps 306936
Displacement Pumps 307862
2 309024
Warnings
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, malfunction, or start unexpectedly and result
INSTRUCTIONS
in serious injury.
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.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
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 plate. Be sure
that all dispensing equipment and accessories are rated to withstand the maximum working pressure 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 displacement 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 180F (82C) or below –40F (–40C).
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
WARNING
SKIN INJECTION HAZARD
Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and
cause 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 cause a hazardous condition and
result in fire, explosion, or electrostatic shock and other serious injury.
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.
4 309024
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.
WARNING
MOVING PARTS HAZARD
Moving parts can pinch fingers.
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 hazardous 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 consequential, 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 volumetric output relationship to the master cylinder, determines 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
the 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.
Airless Spray Dispensing System for
Light Viscosity Fluids
KEY
E Air Supply
F Base Supply
G Catalyst Supply
H Base Supply Pump
J Air Shutoff Valve
K Catalyst Supply Pump
L Air Line Filter
P Static Mixer
R Primary Pump Inlet
T Secondary Pump Inlet
U Solvent Pump
V Airless Spray Gun
X Grounded Fluid Hose
8 Air Pressure Gauge
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 400 psi on the
inbound fluid pressure and never exceed 25% of
the Hydra-Cat pump outbound fluid pressure on
the feed supply.
13 Air Regulator
45 Bleed–type Master Air Valve
46 Pressure Relief Valve
104 Pressure Gauge
120 Mixer Manifold
123 Air Motor
124 Secondary Proportioning Pump (Slave)
H
G
E
K
LJ
123
124
F
X
U
V
45
XXTP
R
8
46
104
13
Fig. 1
6 309024
120
7117B
KEY
A Hydraulic Pump
B Mounting Stand
C Hydraulic Supply Line
D Hydraulic Return Line
E Drain Line (from pressure reducing valve)
F Pressure Gauge
G Flow Control Valve
H Pressure Reducing Valve
J Accumulator
K Feed Pumps
P Hydraulic Supply Line Shutoff Valve
R Hydraulic Return Line Shutoff Valve
S Hydraulic Return Line Filter
U Hydraulic Power Supply
V Fluid Hose
W Fluid Supply Line
Y Pump Ground Wire (required)
Y
A
R
F
P
D
H
K
J
K
U
B
G
E
C
V
S
W
9433A
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 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.
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 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.
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 unexpectedly, resulting in serious injury, including amputation.
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).
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 components 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.
8 309024
Installation
Grounding
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.
1. 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.
W
X
Y
Z
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommendations.
4. Spray gun/dispense valve: ground through connection to a properly grounded fluid hose and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. 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.
Fig. 3
0864
8. 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 application, is the key to easier, more versatile operation of
your proportioning system.
Be sure to read and understand the following information 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.
The secondary pump (124) is on the opposite end of
the lever arm (49). It usually pumps the catalyst. One
or two secondary pumps may be used: one for pumping 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. Set the ratio on the VRHC System.
46
DD
49
30
EE
40
EE
123
38
39
119
124
KEY
DD Manifold Lever
EE Solvent Valves
Fig. 4
10 309024
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 lubricate 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 reducer 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 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 effective areas are listed in Configurator Product Order
Form 309025
118
20%
4
1
4
91%
123
3 3
KEY
HH Lever Arm Index
1
2
3
4
Fig. 5
100%
4
HH
2
124
02368
Primary Stroke –
4” (102 mm)
Secondary Stroke
Effective Area
Index Setting
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.
12 309024
Loading...