Graco 309790ZAA User Manual

Instructions - Parts

8900 Proportioner

309790ZAA

Configured product offering for dispensing fixed or variable ratio of two fluids. For professional use only. Not approved for use in European explosive atmosphere locations.

2000 psi (13.8 MPa, 138 bar) Maximum Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 8 for pump model numbers, ratios and working pressures.

ENG

Fixed-ratio proportioner shown

TI2761A

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 6

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Major Components . . . . . . . . . . . . . . . . . . . . . . . 6

Ratio Proportioning . . . . . . . . . . . . . . . . . . . . . . . 6

System Components and Operation Overview . . 6

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 10

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Set the Ratio (variable ratio models only) . . . . . 14

Output Charts/Ratio Settings . . . . . . . . . . . . . . 15

Before You Load Material . . . . . . . . . . . . . . . . . 18

Load Component A . . . . . . . . . . . . . . . . . . . . . . 19

Prime Pump A . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Load Component B . . . . . . . . . . . . . . . . . . . . . . 21

Prime with Component B . . . . . . . . . . . . . . . . . 24

Fill the 8900 Proportioner with Material . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Pressure Relief Procedure . . . . . . . . . . . . . . . . 27

Dispense Mixed Material . . . . . . . . . . . . . . . . . . 28

Changing Component A Drum . . . . . . . . . . . . . 30

Changing Component B Pail . . . . . . . . . . . . . . . 31

Filling Component B Pressure Tank . . . . . . . . . 32

Daily Procedures . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8900 Proportioner Operating Pressures . . . . . . 36

Air Supply Troubleshooting Chart . . . . . . . . . . . 37

Pump Troubleshooting Overview . . . . . . . . . . . 38

Troubleshooting Guide: Feed pumps . . . . . . . . 39

Troubleshooting Guide: 8900 Proportioner . . . . 40

Troubleshooting Guide: Manifold/Mixer . . . . . . . 41

Preventive Maintenance . . . . . . . . . . . . . . . . . . 42

Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . 43

Repair the Cylinder (Fixed Ratio) . . . . . . . . . . . 43

Replace Air Valve . . . . . . . . . . . . . . . . . . . . . . . 45

Disassemble Fluid Valve . . . . . . . . . . . . . . . . . . . . 46

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8900 Proportioner, Fixed Ratio . . . . . . . . . . . . . 48

8900 Proportioner, Variable Ratio . . . . . . . . . . . 50

Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . 52

Limit Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Pump Feed Module Selection for Component A or

Component B . . . . . . . . . . . . . . . . . . . . . . . 56

20:1 President on 5 Gallon Ram . . . . . . . . . . . . 56

34:1 Senator on 5 Gallon Ram . . . . . . . . . . . . . 58

23:1 Monark on 5 Gallon Ram . . . . . . . . . . . . . 60

20:1 President on 55 Gallon Ram . . . . . . . . . . . 62

34:1 Senator on 55 Gallon Ram . . . . . . . . . . . . 64

31:1 Bulldog on 55 Gallon Ram . . . . . . . . . . . . . 65

20:1 Senator on 55 Gallon Drum . . . . . . . . . . . . 66

9:1 DynaMite on 1 Gallon Can Ram . . . . . . . . . 67

10 Gallon Press Tank with 15:1 Booster . . . . . . 68

10:1 President 5 Gallon Pail Cover . . . . . . . . . . 69

Mix Kit Selection . . . . . . . . . . . . . . . . . . . . . . . . 70

Cartridge Fill Medium Viscosity Wide Ratio . . . 70

Cartridge Fill High Viscosity Wide Ratio . . . . . . 72

Brush Grade High Viscosity Wide Ratio . . . . . . 74

MD2 20 ft Automatic . . . . . . . . . . . . . . . . . . . . . 76

MD2 20 ft Hand Gun . . . . . . . . . . . . . . . . . . . . . 77

MD2 15 ft Hand Gun Wide Ratio Moisture Lock 78

High Volume Static Mix Manifold . . . . . . . . . . . . 79

High Volume Static Mix Kit with Pump Pilots . . . 80

Stanchion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 82

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 86

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 86

2 309790ZAA

309790ZAA 3

Warnings

Skin Injection Hazard

Spray from the gun, hose leaks, or ruptured components can inject fluid through skin and cause extremely serious injury, including need for amputation. Fluid splashed in the eyes or on skin can cause serious injury.

• Fluid injected into skin might look like just a cut, but it is a serious injury. Get immediate surgical

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

• Do not put hand or fingers over the spray tip/nozzle.

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

• Do not “blow back” fluid; this is not an air spray system.

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

• Check gun diffuser weekly. Refer to gun manual.

Warning

treatment.

• Check trigger safety operation before spraying. Lock trigger safety when you stop spraying.

• Follow the Pressure Relief Procedure, page 27, if the spray tip/nozzle clogs and before cleaning,

checking or servicing the equipment.

• Tighten fluid connections before operating equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not repair high pressure couplings; 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.

Toxic Fluid Hazard

Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on skin, swallowed, or inhaled.

• Know specific hazards of the fluid. Read fluid manufacturer’s warnings.

• Wear appropriate protective clothing, gloves, eyewear, and respirator.

4 309790ZAA

Warnings

Warning

Equipment Misuse Hazard

Equipment misuse can cause equipment to rupture, malfunction, or start unexpectedly and cause serious injury.

• This equipment is for professional use only.

• Read manuals, tags, and labels before operating equipment.

• Use equipment only for its intended purpose. If you are uncertain, call your Graco distributor.

• Do not alter or modify equipment. Use only genuine Graco parts and accessories.

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

• Do not exceed maximum working pressure of lowest rated system component.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data sec-

tion of all equipment manuals. Read fluid and solvent manufacturer’s warnings.

• Route hoses away from 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°C).

• Do not kink or overbend hoses or use hoses to pull equipment.

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

• Do not use excessive drum separation air pressure as the drum could rupture. Make sure the drum is not damaged and the ram plate is free to exit the drum before applying air pressure.

Fire and Explosion Hazard

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in fire or explosion and serious injury.

• Ground the equipment and object being sprayed. See Grounding, page 12.

• If you experience static sparking or electric shock, stop operation immediately. Identify and correct the problem.

• Provide fresh air ventilation to avoid building up flammable fumes.

• Keep the spray area free of debris, including solvent, rags, and gasoline.

• Extinguish all sources of flames in the spray area, including pilot lights and cigarettes.

• Do not turn on or off any light switch or plug or unplug electrical equipment in the spray area while operating or if fumes are present.

• Do not operate a gasoline engine in the spray area.

• Keep a fire extinguisher in the work area.

Moving Parts Hazard

Moving parts, such as priming piston and wiper plate, can pinch or amputate fingers. Keep clear of moving parts when starting or operating equipment and when equipment is pressurized.

• Keep hands and fingers away from the priming piston.

• Keep hands away from the ram wiper plate and pail lip.

• Before servicing, follow the Pressure Relief Procedure, page 27, to avoid equipment startup.

309790ZAA 5

Theory of Operation

Use

The 8900 Proportioner is used with two component materials where one or both components is high viscosity. This is typically found in the sealant and adhesive industry, where special requirements for loading and pumping necessitate the use of the 8900 proportioning system.

Major Components

The major components of the 8900 Proportioner system include the:

• Component A or major volume metering cylinder

• Component B or minor volume metering cylinder

• Component A or major volume feed supply

• Component B or minor volume feed supply

Ratio Proportioning

The A and B cylinders are positive displacement metering cylinders. Positive displacement cylinders displace a defined volume of fluid for a given stroke length.

On fixed ratio units, the volumetric ratio is the ratio of the area of the component A displacement cylinder to the area of the component B displacement cylinder. At a 1:1 ratio, the displacement cylinders are the same size. On higher ratio units the component A cylinder is usually the larger of the two. The ratio of the components is the difference in effective area between the cylinders.

On variable ratio units, the component B cylinder has an adjustable stroke length. The component A cylinder has a fixed stroke length. By setting the stroke adjustment to different points on the connecting linkage, you can change the stroke length of the B cylinder, which changes the mix ratio. You can calculate the material mix ratio from the ratio of the cylinder displacement volume.

System Components and Operation Overview

Feed Systems - Feed Pumps

Load the Feed Pumps and Proportioner

The A and B feed pumps/cylinders must completely fill (prime) on both strokes to ensure accurate material displacement.

With high viscosity materials, it is difficult for material to flow into the pump. Individual feed pumps are used to supply these materials under pressure to the 8900 Proportioner. When air is trapped in the feed system due to improper loading, a condition called cavitation occurs.

If cavitation occurs, part of the downstroke will be used to fill the vacuum before any material is actually displaced. Since the total stroke length is used to calculate mix ratio, this may result in an off-ratio condition.

To prevent cavitation with higher viscosity materials, both cylinders are pressure fed. The A pump is pressurized by a pneumatic ram supply unit applying a downward force on a 55-gallon plate fitted into the drum. A shovel action pump fluid inlet further aids in pump priming. Component B is delivered to the B pump by pressure fed 5- or 55-gallon supply modules, depending on the volumetric ratio of the material.

Pneumatic ram assisted feed pumps may not be required for lower viscosity materials.

Feed Systems - Alternative Feed Supplies

Header or other feed systems may be used to supply A and B materials to the 8900 Proportioner. Generally these feed systems are provided by others and are not addressed in this manual. This manual applies only to the Graco Configured 8900 Proportioner system.

Note that the mix ratio of the 8900 Proportioner is achieved by volumetric ratio of component A to component B and not by weight. These two ratios are often different depending on material properties.

6 309790ZAA

Theory of Operation

Pump Fluids to the Mixer

Fluid is pumped through the proportioner to a mix chamber or to a 2-component dispense gun, where component A and component B are first introduced before being mixed with a static mixer.

A fluid injector nozzle/check valve injects component B into component A at the mix chamber. When enough pressure builds up, the check valve opens and component B flows into the mix chamber. This means that during flow conditions with two positive displacement cylinders linked together, the pressures at the mix point are equal.

Any pressure differences noted on the gauges while running, reflect differences in the pressure lost by each fluid getting from the gauge to the mix point. These pressure drops are caused by hoses and fittings in conjunction with material viscosity.

Mix the Fluids

Both components leave the mix chamber and enter a static mixer where they are mixed to a homogeneous blend. The mixer consists of a series of left and right-hand spiral elements. This is true for both mix chamber and 2-component mix gun.

Some 8900 Proportioners use a 2K disposable mixer element dispense valve instead of the flow gun.

The 8900 Proportioner can be used in automatic assembly lines with the addition of a logic interface.

When the components are pumped through the mixer, they are progressively divided and recombined. Static mixers used on the 8900 Proportioner system include the tri-core mixer, flexible hose mixer, or disposable mixer.

Ratio Checks

On the variable ratio model, a ratio check station option verifies the volumetric mix ratio of the two components. It is located at the outlet blocks. With all outbound fluid valves closed, each component flows through individual ball valves opened by a common handle into containers.

Volumetric mix ratio can be calculated from the weight of each component or by direct measurement. Ratio checks are performed with the back pressures set to actual operating pressures to simulate the normal back pressures created by the mix chamber and gun.

Dispense Valve

An extrusion flow gun is commonly used as the applica- tion device. It has a final or clean up mixer installed in the handle. Various extrusion nozzles are available for caulking or sealing applications.

309790ZAA 7

Models

Refer to form 684041 for selection information.

Model Description

890-D Power Valved Passive Proportioner

Code A Proportioner Selection (“A” Cyl. / “B” Cyl.) Module Number

1 1:1 Fixed (1000/1000) 570371 2 2:1 Fixed (1000/500) 570372 3 2.5:1 Fixed (250/100) 570373 4 4:1 Fixed (1000/250) 570374 5 5:1 Fixed (500/100) 570375 6 10:1 Fixed (1000/100) 570376 7 9:1 Fixed (1000/111) 246557 A 1:1 to 4:1 Variable (500/500) 570377 B 2:1 to 8:1 Variable (500/250) 570378

D 5:1 to 20:1 Variable (500/100) 570380

Code B Pump Feed Module Selection for Component A Module Number

A 20:1 President on 5 Gallon Ram 965571 B 34:1 Senator on 5 Gallon Ram 965597 C 23:1 Monark on 5 Gallon Ram 570142 D 20:1 President on 55 Gallon Ram 570114 E 34:1 Senator on 55 Gallon Ram 965572 F 31:1 Bulldog on 55 Gallon Ram 570141 G 20:1 Senator on 55 Gallon Drum 570309 H 9:1 DynaMite 1 Gallon Can Ram 570249

J 10 Gallon Press Tank with 15:1 Booster 570037 K 10:1 President 5 Gallon Pail Cover 570264 NNone

Code C Pump Feed Module Selection for Component B Module Number

J 10 Gallon Press Tank with 15:1 Booster 570037 K 10:1 President 5 Gallon Pail Cover 570264 NNone

8 309790ZAA

Code D Mix Kit Selection Module Number

1 Cart Fill Medium Viscosity Wide Ratio 570248 2 Cart Fill High Viscosity Wide Ratio 570318 3 Brush Grade High Viscosity Wide Ratio 570358 4 MD2 20 ft Automatic Wide Ratio 24H258 5 MD2 20 ft Automatic Close Ratio 24H259 6 MD2 20 ft Hand Gun Wide Ratio 24H260 7 MD2 20 ft Hand Gun Close Ratio 24H261 8 MD2 15 ft Hand Gun Wide Ratio Moisture Lock 24H243 9 High Volume Static Mix Kit with Pump Pilots 570263

NNone

Code E Mounting Type Selection Module Number

1 Stanchion 570071 2 Boom Assembly 246589

N None (mount on 3 in. 55 gallon ram)

Models

309790ZAA 9

Installation

Typical Installation

Figures 1-3 are only guides for selecting and installing system components and accessories. Contact your Graco distributor for assistance in designing a system to suit your needs.

Location

Position the feed modules so the pump and ram are easily accessible. Ensure that there is sufficient overhead clearance when the ram is fully raised. Refer to the ram manual for clearance dimensions.

Using the holes in the ram base as a guide, drill four holes for 1/2 in. (13 mm) anchors.

Key:Figs. 1 and 2

A System Air Shutoff Valve (bleed-type) B Main Air Filter C Component B Ram Directional Valve D Component B Ram Air Pressure Regulator E Component B Air Supply Valve (bleed-type) F Component B Air Supply Regulator G Component A Air Supply Valve H Component B Outlet Pressure Gauge J Component B Feed Pressure Gauge K Component A Feed Pressure Gauge

(behind)

Check that the ram base is level in all directions. If necessary, level the base using metal shims. Secure the base to the floor using 1/2 in. (13 mm) anchors that are long enough to prevent the ram from tipping.

L Component A and Component B Feed Pump Air

Motor Lubricator M Component B Ram Plate with Vent Stick or Valve N Component A Ram Plate with Drum Vent Valve O Component A Pump Air Regulator P Component A Ram Directional Valve Q MD2 Gun with Disposable Mixers R Component A Ram Air Pressure Regulator S Accessory/Gun Air Supply Valve

(behind)

WARNINGWARNING WARNINGWARNING

INSTRUCTIONS INSTRUCTIONS

READ MANUAL BEFORE OPERATING

DISPENSE MIXED MATERIAL

ADJUST FLOW RATE

DRUM OR PAIL CHANGE

"B" PUMP

PRESSURE ADJUSTMENT

BASE PURGE AND SHUT-DOWN

REFILLING PRESSURE POT

(IF EQUIPPED)

PUMPS

ONOFF

"A" PUMP

PRESSURE ADJUSTMENT

8900

PROPORTIONER

WARNINGWARNING

High pressure device for professional use only.

Read instruction manual before operating. Observe all warnings.

MAIN AIR

OFF ON

MAIN AIR

INLET

FIG. 1:

10 309790ZAA

ti16735a

Installation

Supply header system supplied by others (not covered in this manual).

Component B Supply Header

Component B Fluid Regulator

FIG. 2:

Key:FIG. 3

Q2K Gun V Disposable Mixer Element W Component B Injector Valve

(behind)

INSTRUCTIONS INSTRUCTIONS

READ MANUAL BEFORE OPERATING

DISPENSE MIXED MATERIAL

ADJUST FLOW RATE

DRUM OR PAIL CHANGE

"B" PUMP

PRESSURE ADJUSTMENT

(behind)

Component A Supply Header

Component A Fluid Regulator

WARNINGWARNING WARNINGWARNING

8900

PROPORTIONER

WARNINGWARNING

High pressure device for professional use only.

Read instruction manual before operating. Observe all warnings.

MAIN AIR

OFF ON

MAIN AIR

INLET

BASE PURGE AND SHUT-DOWN

REFILLING PRESSURE POT

(IF EQUIPPED)

PUMPS

ONOFF

"A" PUMP

PRESSURE ADJUSTMENT

ti16759a

X Air Trigger Pilot Y Component B Supply Z Component A Supply

ti16737a

FIG. 3

309790ZAA 11

Installation

Ground

WARNING

The system must be properly grounded. Read warnings, page 5. Follow the instructions below.

Pump: use the ground wire and clamp (supplied). There are two styles of ground connections on pump air motors.

If you have the ground screw (a) shown in F

(King air motor only), order part no. 222011 ground wire, ring terminal, and clamp assembly (b). To install 222011, remove the ground screw (a) and insert it through the eye of ring terminal (c), then tighten ground screw back into air motor as shown in F

IG. 4. Connect

the other end of the wire to a true earth ground.

IG. 4

Air and fluid hoses: use only electrically conductive

hoses with a maximum of 500

ft (150 m) combined hose

length to ensure grounding continuity. Check the electrical resistance of your air and fluid hoses. If the total resistance to ground exceeds 29 megohms, replace the hose immediately.

Air compressor: follow manufacturer’s recommendations.

Spray gun/dispense valve: ground through connection to a properly grounded fluid hose and pump.

Fluid supply container: follow your local code.

Substrate: follow your local code.

Solvent pails used when flushing: follow your local

code. Use only conductive, metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure: hold a metal part of the gun/dis-

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

IG. 4: Ground Screw (King air motors only)

If you have the ground screw (d) shown in F

IG. 5,

loosen the grounding lug locknut (g) and washer (f). Insert one end of the ground wire (e) into the slot in lug (d) and tighten the locknut securely. Connect the other end of the wire to a true earth ground. Order 237569 ground wire and clamp assembly.

f d

IG. 5 Ground Screw

12 309790ZAA

Installation

Flush

WARNING

Read warnings, pages 4-5. Follow Ground instructions, page 12.

• The equipment was tested with light, soluble oil. Flush the system before loading material to avoid contamination.

• Flush at the lowest pressure possible and check connectors for leaks.

To flush the system:

1. On the ram-mounted component A supply units, you must remove the drum ram plate to immerse the A pump in a solvent pail. To remove the plate:

a. Disconnect the blow-off air line from the ram

plate.

b. Disconnect the tie rod nuts from the ram cross

beam.

2. Flush the system and all hoses by very slowly opening the motor control valves until 30 psi (207 kPa,

2.1 bar) is shown on the component A outlet pressure gauge.

Flush for 1-2 minutes, then close the motor control valves.

CAUTION

To avoid damaging the pump, open the motor control valves very slowly to prevent a pump runaway condition.

It is normal for the air valve to exhaust air when it is partially open.

3. Check connectors for leaks and tighten them if necessary.

4. Remove the solvent pail(s) from the pump inlets.

5. Operate the pump(s) at low pressure to remove excess solvent.

6. Reinstall the drum or pail ram plates.

c. Remove seal plates between the pump and

ram.

d. Loosen ram tie rods from plate and remove

plate.

e. If a pail ram is used with the component B sup-

ply, remove the pail plate by loosening the 2 set screws.

f. Position the solvent pail so the pump inlet is in

the solvent.

Use solvent that is compatible with the equipment wetted parts and the material you will dispense.

g. Support the ram(s) so that the pump inlet and

piston will not hit the base plate or pail bottom.

h. Make sure both component A and component B

outlet hoses are open.

309790ZAA 13

Setup

WARNING

Read warnings, pages 4-5, before operating equipment.

Set the Ratio (variable ratio models only)

Adjust ratio

The ratio of this unit is produced partially by the difference in the area of the metering cylinders and partially by the position of the adjustable fulcrum point in the Unibar linkage assembly. With the fulcrum point in the center, each meter cylinder strokes 3 in. (10.16 cm). In the center position, the dispense ratio is the same as the meter cylinder ratio.

The linkage is adjustable depending on the location of the fulcrum point. The linkage must be adjusted for each material application so the combined linkage and meter cylinder ratio equals the desired material mix ratio by volume. The ratio may be checked by weight, but the machine meters by volume and that ratio must be known before proceeding.

The initial linkage adjustment point can be calculated by inserting known values into the formula on page 35. The result is the distance in inches from the center of the fulcrum point to the center of the component B meter cylinder. For convenience, measure the distance between the grease fitting on the top of the fulcrum and the center of the component B cylinder meter rod.

FIG. 6

Set Scale

Refer to the 8900 Proportioner Output Charts on the following pages to set the scale. Make final adjustments after the material is loaded. See instructions on page 33 for detailed ratio check instructions.

14 309790ZAA

Output Charts/Ratio Settings

8900 Proportioner, 1:1 - 4:1 Variable Ratio

Mix Ratio by Volume Scale Setting Minor Stroke

1 5.63 3.00

1.5 7.13 2.00 2 8.13 1.50

2.5 8.85 1.20 3 9.38 1.00

3.5 9.80 0.86 4 10.13 0.75

Setup

Setting in Inches from Pivot or Minor Stroke

Mix Ratio by Volume

Scale Settin

Minor Stroke

1 1.5 2 2.5 3 3.5 4

5.63 7.13 8.13 8.85 9.38 9.80 10.13

3.00 2.00 1.50 1.20 1.00 0.86 0.75

309790ZAA 15

Setup

8900 Proportioner, 2:1 - 8:1 Variable Ratio

Mix Ratio by Volume Scale Setting Minor Stroke

2 5.63 3.00 3 7.13 2.00 4 8.13 1.50 5 8.85 1.20 6 9.38 1.00 7 9.80 0.86 8 10.13 0.75

Setting in Inches from Pivot or Minor Stroke

Mix Ratio by Volume

Scale Settin

Minor Stroke

2345678

5.63 7.13 8.13 8.85 9.38 9.80 10.13

3.00 2.00 1.50 1.20 1.00 0.86 0.75

16 309790ZAA

8900 Proportioner, 5:1 - 20:1 Variable Ratio

Mix Ratio by Volume Scale Setting Minor Stroke

5 5.63 3.00 7 7.13 2.00

10 8.13 1.50 12 8.85 1.20 15 9.38 1.00 17 9.80 0.86 20 10.13 0.75

Setup

Setting in Inches from Pivot or Minor Stroke

Mix Ratio by Volume

Scale Settin

Minor Stroke

5 7 10 12 15 17 20

5.63 7.13 8.13 8.85 9.38 9.80 10.13

3.00 2.00 1.50 1.20 1.00 0.86 0.75

309790ZAA 17

Setup

Before You Load Material

1. Check fluid and air lines and tighten if necessary.

2. Make sure there is a minimum overhead clearance of 110 in. (279 cm) for 55 gallon supply.

3. Fill air line lubricator for the 8900 Proportioner module with SAE 10 W non-detergent oil (not included).

4. Fill the pump A and B wet cups 2/3 full with Graco T.S.L. fluid (throat seal lubricant) or lubricant compatible with material being pumped.

ISO pump oil is used with moisture sensitive component B.

5. Close (turn fully counterclockwise) all air regulators.

6. Connect the 3/4 in. (19 mm) ID x 10 ft (3.05 m) air hose (provided) to your air supply.

Do not use a restrictive quick-disconnect. The air supply pressure must be consistently above the pressure you set on the main air motor regulator.

Wet Cup

TI3263Ax

IG. 7

18 309790ZAA

Load Component A

1. Make sure all air regulators on proportioner module are fully closed.

Setup

2. Open the main air supply shutoff valve (A), F

3. Place the ram lever (P-F

IG. 10) in the UP position.

IG. 8.

CAUTION

As the ram rises, make sure hoses do not catch on any components. If a hose catches, immediately stop the ram (move lever to NEUTRAL position) and correct the problem. Lower the ram if necessary to redirect hoses.

4. Slowly turn the ram air regulator (R) clockwise until the ram begins rising.

FIG. 9

WARNING

When lowering the ram, keep hands and body away from the ram plate and material drum. Read warnings, page 5.

9. With hands away from the pail and wiper plate (N), set the ram lever (P-F

IG. 10) to NEUTRAL (horizon-

tal position). Let the ram lower until the wiper plate rests on the pail lip.

10. Lower the ram plate into the drum (move ram lever to DOWN position).

IG. 8

5. When ram is fully raised, apply a thin coating of lubricant to the ram plate drum seals.

6. Open the material container. Remove any packing materials, and inspect for material contamination. If the container has a plastic liner, pull it tightly over the sides of the container, and secure the liner in place with tape wrapped below the top drum rim.

7. Position the drum so it rests evenly between the centering guides and is fully backed into the stops located near the back of the ram base plate.

8. Open the drum vent valve (W), F

IG. 9.

CAUTION

Do not lower ram if a drum is not in place. Doing so can damage drum centering guides.

Ram Separation

Air Button

FIG. 10

11. After the ram plate seals contact the drum, adjust the ram air regulator (R) to about 30-50 psi (207-345 kPa, 2.1-3.4 bar).

12. When the ram stops and material fills the bleed port (or air stops bleeding out), close the drum vent valve (W), F

IG. 9.

13. Supply unit is now ready to fill lines to proportioner.

309790ZAA 19

Setup

Prime Pump A

1. Place a waste container under the pump bleed valve located behind the displacement pump outlet, F

11. Using an adjustable wrench, open the bleed valve counterclockwise 1/3-1/2 turn.

Bleed Valve

IG. 11

IG.

2. Slowly open the component A air motor shutoff valve (G), F

IG. 7. Make sure the pump begins to

cycle and material flows from the bleed valve after several cycles of the pump, F

IG. 11.

If the pump does not cycle, close the air shutoff valve (G), adjust the air motor regulator (O-F

IG. 8)

up 5 psi (34 kPa, 0.3 bar) and repeat step 2. Never adjust the regulator by more than 5 psi (34 kPa, 0.3 bar) increments.

3. Operate the pump until it moves smoothly in both directions with no air popping or erratic movement, then close the air motor shutoff valve (G).

4. Close the bleed valve, F

IG. 11.

20 309790ZAA

Setup

Load Component B

Follow the procedure for the type of supply equipment being used.

Pneumatic Pail Ram and Piston Pump

1. Close all air regulators and air valves.

2. Set the pail ram air regulator (D) to 40 psi (0.28 MPa, 2.8 bar), F

3. Push the ram directional lever (C) to the UP position and let the ram rise to its full height.

4. When ram is fully raised, apply a thin coating of lubricant to the ram plate drum seals.

5. Remove the component B pail cover. If the material has separated, carefully stir it with a metal or plastic rod until it is mixed. Do not use wood to stir as it can splinter and contaminate the material. Do not mix air into the material.

6. Set the pail on the ram base. Slide it back toward the ram tube and supports and center it under the wiper plate. To prevent air from being trapped under the wiper plate, scoop fluid from the center of the pail to the sides to make the surface concave.

IG. 12.

WARNING

When operating the pump or raising or lowering the ram, keep hands away from the wiper plate, fluid container lip, and pump intake. Read warnings, page 5.

7. With hands away from the pail and wiper plate, set the ram lever (C) to NEUTRAL (horizontal position). Let the ram lower until the wiper plate rests on the pail lip.

8. Ensure the pail is aligned with the wiper plate.

9. Push the ram directional lever (C) DOWN and increase ram air pressure until plate completely engages into the pail.

10. Slowly unscrew the vent stick until you hear air escaping. When air is evacuated, set the ram lever (C) to NEUTRAL and lower ram pressure to 20-30 psi (138-207 kPa, 1.4-2.1 bar).

11. Unscrew the vent stick and put the ram lever (M) in the DOWN position, keeping the vent stick over the vent port.

12. Slowly increase down pressure until material seeps from vent port, the quickly refasten vent stick.

309790ZAA 21

Setup

FIG. 12

Wiper Plate

TI3260B

22 309790ZAA

Setup

Pressure Tank with 15:1 Booster

1. Relieve tank pressure before opening.

2. Remove the pressure tank lid and any items shipped inside the tank. Make sure the tank is clean, or use the liner supplied.

3. Be sure the desiccant air dryer is mounted in the component B tank air supply of the proportioner air control module. See F

4. Gently roll an unopened pail of component B on the floor for several revolutions to mix it.

5. Open the pail outlet and carefully pour component B into the tank.

6. Immediately close the tank by tightening the Thandles (GG) evenly, F

IG. 28, page 32.

IG. 13.

7. Pressurize the tank with dried air by opening the component B air shutoff valve (S) and the pressure tank air shutoff valve (T), Figures 14 and 15.

IG. 14

8. Set the component B tank air regulator (U) to approximately 40 psi (276 kPa, 2.8 bar).

9. Check to ensure the air valve (E) to booster pump is turned off and material supply ball valve (KK) is closed.

10. Set feed pump regulator (F) on proportioner assembly to approximately 40 psi (276 kPa, 2.8 bar).

IG. 13

From component B pump air regulator on proportioner module.

To component B inlet on proportioner

11. The unit is ready to feed material to proportioner.

Pump

Booster

From air manifold on proportioner module.

TI3259Ay

FIG. 15

309790ZAA 23

Setup

Prime with Component B

1. Place a waste container under the pump bleed valve located behind the displacement pump outlet, F

16. Using an adjustable wrench, open the bleed valve counterclockwise 1/3-1/2 turn.

Bleed Valve

IG. 16

2. Slowly open the component B air motor shutoff valve (E), F

IG. 15. Make sure the pump begins to

cycle and material flows from the bleed valve after several cycles of the pump, F

IG. 16.

IG.

Fill the 8900 Proportioner with Material

1. Place a material waste container under dispense gun (Q) and open gun. F

2. Open the main ball valve (A-F tioner assembly. This air valve supplies air to the proportioner control valving and to the feed pump assemblies. All other air shut-off valves on the manifold and feed pump assemblies should be off.

3. Open the feed pump main air valve (S). This allows the air supply to feed pump assemblies.

4. Adjust the component B supply pump air regulator (F) to allow smooth pumping action. Continue until component B flows from the dispense gun into the waste container.

The minor or component B side of material is filled first to minimize waste during initial startup.

5. Adjust the component A air regulator (O) to allow smooth pumping action.

IG. 1, page 10.

IG. 17) on the propor-

If the pump does not cycle, close the air shutoff valve (E), adjust the air motor regulator (F-F

IG.

17) up 5 psi (34 kPa, 0.3 bar) and repeat step 2. Never adjust the regulator by more than 5 psi (34 kPa, 0.3 bar) increments.

3. Operate the pump until it moves smoothly in both directions with no air popping or erratic movement, then close the air motor shutoff valve (E), F

4. Close the bleed valve, F

IG. 16.

IG. 15.

6. Pump until component A and component B flow from the gun into the waste container. When the material is bubble-free, all air has been purged from the system.

7. Turn off air supply valve (S).

8. Close dispense gun.

9. The 8900 Proportioner is now filled with components A and B and ready for operation.

OS A

IG. 17

24 309790ZAA

MD2 Disposable Mixer Gun Models

Follow steps 10-12.

10. Fit the hose to the gun. Trigger the gun into a waste container.

Setup

11. Open the component B feed air shutoff valve (E-F

15). Component B will feed through the metering cylinder to the mix gun.

12. When bubble free material is dispensed, stop triggering the gun.

All Models

The system is now ready to dispense mixed material.

CAUTION

The materials will cure after mixing. Purge the mixer, hose, and gun with clean material before the material begins to cure.

IG.

309790ZAA 25

Setup

26 309790ZAA

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