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Hydra-Mate 308930K
ENG
For proportioning, mixing, pumping, and dispensing high viscosity, wide ratio materials.
For professional use only.
9472a
Manual Conventions
Warning Caution
WARNING CAUTION
A caution alerts you to the possibility of damage to or
destruction of equipment if you do not follow instruc-
A warning alerts you to the possibility of serious injury tions.
or death if you do not follow the instructions.
Symbols, such as fire and explosion (shown), alert you Note
to a specific hazard and direct you to read the indi-
A note indicates additional helpful information.
cated hazard warnings (pages 3-4) for detailed infor-
mation.
2 308930K
Warning
WARNING
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
treatment.
• 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.
• Check trigger safety operation before spraying. Lock trigger safety when you stop spraying.
• Follow the Pressure Relief Procedure, page 24, 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.
308930K 3
Warning
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause equipment to rupture, malfunction, or start unexpectedly and cause seri-
ous injury.
• Ground the equipment and object being sprayed. See Grounding, page 10.
• 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.
MOVING PARTS HAZARD
Moving parts, such as priming piston and wiper plate, can pinch or amputate fingers. Keep clear of mov-
ing parts when starting or operating equipment and when equipment is pressurized.
4 308930K
Theory of Operation
Theory of Operation
Usage System Components and
Hydra-Mate is used with two component materials Operation Overview
where one or both components are heavy. This is typi-
cally found in the sealant and adhesive industry, where Loading the Pumps
special requirements for loading and pumping necessi-
tate the use of the Hydra-Mate system. The resin and catalyst pumps must completely fill
(prime) during the loading stroke, to ensure accurate
material displacement.
Major Components
With high viscosity materials, it is difficult for material to
The major components of the Hydra-Mate system flow into the pump on the loading stroke. A vacuum
include the: forms during the piston upstroke, similar to trying to
draw thick fluid into a hypodermic syringe. This condition
• air motor is called pump cavitation.
• resin or master pump
• catalyst or slave pump If cavitation occurs, part of the downstroke will be used
• ram to fill the vacuum before any material is actually dis-
• catalyst feed supply placed. Since the total stroke length is used to calculate
• mixer manifold or 2K gun mix ratio, this results in an off-ratio condition.
• mixer
• ratio check station To prevent cavitation, both pumps are pressure fed. The
• application device resin pump is pressurized by a pneumatic ram applying
a downward force on a 55 gallon plate fitted into the
Frame drum. A shovel action pump fluid inlet further aids in
pump priming. Catalyst is delivered to the slave pump by
The air motor supplies the force and motion required to a pressure fed 5 gallon supply module.
drive the system. A connecting rod couples the master
pump and air motor directly. Air motor force and motion Pumping the Fluids to the Mixer
is transmitted through the slave linkage for synchronous
motion of the master and slave pumps. Fluid is pumped through outlet blocks to a mix manifold,
where resin and catalyst are first introduced before
being mixed in a static mixer.
Ratio Proportioning
A check valve injects catalyst into resin at the mix mani-
The master and slave pumps are positive displacement
fold. When enough pressure builds up, the check valve
pumps. Positive displacement pumps displace a defined
opens and catalyst flows into the mix manifold. This
volume of fluid for a given stroke length. The pumps dis-
means that during flow conditions with two positive dis-
place equal amounts of material on the up and down
placement pumps linked together, the pressures at the
strokes but load or prime only on the up stroke.
mix point are equal.
The master and slave pumps displace different volumes
Any pressure differences noted on the gauges while
for the same stroke length. By adjusting the slave inlet
running reflect differences in the pressure lost by each
manifold to different points on the slave linkage, you can
fluid getting from the gauge to the mix point. These
change the stroke length of the slave pump, which will
pressure drops are caused by hoses and fittings.
change the mix ratio. You can calculate the material mix
ratio from the ratio of the pump displacement volume.
Mixing the Fluids
Note that the mix ratio of the Hydra-Mate is achieved by
Both components leave the mix manifold and enter a
volumetric ratio of resin to catalyst and not by weight.
static mixer where they are mixed to a homogeneous
These two ratios may be different depending on material
blend. The mixer consists of a series of left and
properties.
right-hand spiral elements.
308930K 5
Theory of Operation
Ratio Checks
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 com-
ponent flows through individual ball valves opened by a
common handle into containers.
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.
6 308930K
Models
Models
Refer to form 684038 for selection information.
Model Description
VRHM Variable Ratio Hydra-Mate
Code A Proportioner Pump Modules Module Number
1 25:1 Bulldog, #7 slave 7.5-16.5:1 Mix 953100
2 25:1 Bulldog, #1 slave 3.7-8.0:1 Mix 570312
3 50:1 Quiet King, #7 slave 7.5-16.5:1 Mix 954900
5 50:1 Quiet King, #5 slave 6.5-13.5:1 Mix, T-Wipers on 55 gal. (208 l) Ram 965580
Code B Curative Feed Modules Module Number
1 5:1 Monark on 5 gal. Ram Kit 954855
2 5 gal. Pressure Tank Kit 948109
N None
Code C Boom and/or Hose Kits to Supply Gun Kits (Code D) Module Number
1 Boom Kit with 10 ft. (3.05 m) hoses to end for silicone or urethane 570293
2 Boom Kit with 10 ft. (3.05 m) hoses to end for polysulfide 570039
3 10 ft. (3.05 m) Hose Extension Kit for silicone or urethane 570342
4 10 ft. (3.05 m) Hose Extension Kit for polysulfide 570381
N None
Code D Mix and Dispense Kits (connects to one of Code C) Module Number
1 Resin Purge Flexible Mixer polysulfide 10 ft. (3.05 m) hoses 570292
2 Resin Purge Flexible Mixer silicone 10 ft. (3.05 m) hoses 570294
3 Resin Purge Flexible Mixer urethane 10 ft. (3.05 m) hoses 570295
4 Resin Purge Tri-Core Mix polysulfide 10 ft. (3.05 m) hoses 570382
5 Resin Purge Tri-Core Mix silicone 10 ft. (3.05 m) hoses 570383
6 Resin Purge Tri-Core Mix urethane 10 ft. (3.05 m) hoses 570384
7 MD2 Disposable Mixer polysulfide 10 ft. (3.05 m) hoses 570184
8 MD2 Disposable Mixer silicone 10 ft. (3.05 m) hoses 570304
9 MD2 Disposable Mixer urethane 10 ft. (3.05 m) hoses 570225
Code E Accessories Module Number
1 Ratio Check Nozzle Kit 233415
N None
308930K 7
Installation
Installation
Typical Installation
FIG. 1-3 is only a guide for selecting and installing system components and accessories. Contact your Graco distribu-
tor for assistance in designing a system to suit your needs.
Key:
A System Air Shutoff Valve (bleed-type) L Catalyst Feed Pressure Gauge
B Main Air Filter M Ratio Check Outlet Valves
C Ram Directional Valve N Catalyst Feed Pump Air Motor Lubricator
D Ram Air Pressure Regulator O Catalyst Strainer (20 mesh)
E Catalyst Air Supply Valve (bleed-type) P Pail Air Blow-off and Return Line Check Valves
F Catalyst Air supply Regulator Q Vent Stick or Valve
G Main Air Motor Shutoff Valve (bleed-type) R Ram Plate with drum vent valve
H Catalyst Bypass Valve (back to supply) S Main Pump Air Regulator
I Catalyst Outlet Filter T Main Pump Bleed Valve
J Catalyst Outlet Pressure Gauge U MD2 Valve with disposable mixers
K Resin Outlet Pressure Gauge V Main Motor Lubricator (not visible in FIG. 1)
K J I V H
VARIABLE RATI
HYDRA-MATE S O
YC
.C .N G
F
RESIN CATLAYS .O .N
OUTLET OUTLET
FLUID
FILTER
AI
MOTO
GRAC
E
FEED
AI
GRAC
D
DRUM
RA C
M MAIN
AI
A GRAC
O F
MONARK
U N
R B
T
ti16581a Q
P
Location
Position the ram so the air regulators for the pump and Check that the ram base is level in all directions. If nec-
ram are easily accessible. Ensure that there is sufficient essary, level the base using metal shims. Secure the
overhead clearance when the ram is fully raised. Refer base to the floor using 1/2 in. (13 mm) anchors which
to the ram manual for clearance dimensions. are long enough to prevent the ram from tipping.
8 308930K
Installation
Key:
W Air Line, Pressure Pot; 1/4 in. ID AA Fluid Supply Line; 1/2 npt (mbe) x 10 ft (3.05 m)
X Fluid Return Line; 1/4 in. npsm (fbe) x 10 ft (3.05 m) AB Air Line, Ram; 1/4 in. ID x 10 ft (3.05 m)
Y Fluid Supply Line; 3/8 in. npt (mbe) x 10 ft (3.05 m) AC Air Line, Pump; 1/2 in. ID x 10 ft (3.05 m)
Z Pressure Pot AD Air Line, Main; 3/4 npt (mbe) x 10 ft (3.05 m)
AA
VARIABLE RATIO
HYDRA-MATE
W
C
.C.N
LYC
RESIN CATLAYST .O .N
OUTLET OUTLET
FLUID
FILTER
AB W REF
AIR GRACO
M OT O R
FEED
AIR
GRACO
AC X
DRUM
RAM
GRACO
Y
MAIN
AIR
O F F
MONARK
Z
GRACO
AD AD
Catalyst Pail Pump Feed - see page 46 Catalyst Pressure Tank Feed - see page 48
FIG. 2
Key:
AE Mix and Gun Kit; resin purge with Tri-Core Mixer AI Tri-Core Mixer
AF Mix and Gun Kit; resin purge with Flexible Mixer AJ Flexible Mixer
AG Catalyst Shutoff Valve AK Gun Handle Static Mixer (inside)
AH Catalyst Injector Valve AL Gun Hose Swivel
AK
AL
AK
AL AJ
AI AH
AH AG
AG
AE
AF
FIG. 3
UP
ED
LIN
S
RK
MA
P
CA
D
EN
H
WIT
E
BL
EM
ASS
308930K 9
Installation
Grounding
W
. Y
WARNING X
Z
If you have the ground screw (Z) shown in FIG. 5, Air compressor: follow manufacturer’s recommenda-
loosen the grounding lug locknut (W) and washer (X). tions.
Insert one end of the ground wire (Y) into the slot in lug
(Z) and tighten the locknut securely. Connect the other Spray gun/dispense valve: ground through connection
end of the wire to a true earth ground. Order 237569 to a properly grounded fluid hose and pump.
ground wire and clamp assembly.
Fluid supply container: follow your local code.
10 308930K
Installation
Flushing
CAUTION
To avoid damaging the pump, open the motor control
WARNING
valves very slowly to prevent a pump runaway condition.
Read warnings, pages 3-4. Follow Grounding instruc- It is normal for the air valve to exhaust air when it is
tions, page 10. partially open.
• The equipment was tested with light, soluble oil. 3. Check connectors for leaks and tighten them if nec-
Flush the system before loading material to avoid essary.
contamination.
4. Remove the solvent pail(s) from the pump inlets.
• Flush at the lowest pressure possible and check
5. Operate the pump(s) at low pressure to remove
connectors for leaks.
excess solvent.
To flush the system: 6. Reinstall the drum or pail ram plates.
308930K 11
Setup
Setup
WARNING
Volume Adjustment
To adjust the volume of material displaced by the slave
pump (AA), loosen the clamping bolts (BB) on the
adjuster at the bottom of the frame. See FIG. 7. Slide the CC
adjuster along the setpoint scale (CC). Move adjuster
BB
toward the master pump to increase volume (closer
ratio) and away from the master pump to decrease vol-
ume (wider ratio). See FIG. 6. Refer to the scale on the
pivot arm. It may be necessary to jog the air motor with
the air control ball valve to reposition the adjuster. When
adjuster is in desired position, tighten the bolts (BB).
FIG. 7
De V
cre olum
as
e e
Inc
rea
se
FIG. 6
Scale Setting
Refer to the Hydra-Mate Output Charts on the following
pages to set the scale. Make final adjustments after the
material is loaded. See manual 309207 for detailed ratio
check instructions.
12 308930K
Setup
Output Charts
Hydra-Mate Module 953100
Mix Ratio Scale Slave Fluid/Air Output
By Volume Setting Stroke Pressure Ratio Per Cycle cc's
6
Setting in Inches from Pivot or Slave Inches of Travel
Scale
Setting
3 Slave
Stroke
0
7.40 7.75 8.14 8.57 9.04 9.57 10.17 10.85 11.62 12.52 13.56 14.79 16.27
308930K 13
Setup
6.00
Setting in Inches from Pivot or Slave Inches of Travel
5.00
4.00
Scale
Setting
3.00 Slave
Stroke
2.00
1.00
0.00
3.70 3.87 4.07 4.28 4.52 4.79 5.09 5.42 5.81 6.26 6.78 7.40 8.14
14 308930K
Setup
6.00
Setting in Inches from Pivot or Slave Inches of Travel
5.00
4.00
Scale
Setting
Slave
3.00
Stroke
2.00
1.00
0.00
7.40 7.75 8.14 8.57 9.04 9.57 10.17 10.85 11.62 12.52 13.56 14.79 16.27
308930K 15
Setup
6.00
Setting in Inches from Pivot or Slave Inches of Travel
5.00
4.00
Scale
Setting
3.00 Slave
Stroke
2.00
1.00
0.00
6.16 6.46 6.78 7.14 7.53 7.98 8.48 9.04 9.69 10.43 11.30 12.33 13.56
16 308930K
Setup
DD C
FIG. 8
FIG. 9
5. Close (turn fully counterclockwise) all air regulators.
5. Apply a thin coating of lubricant to the ram plate
6. Connect the 3/4 in. (19 mm) ID x 10 ft. (3.05 m) air drum seals.
hose (provided) to your air supply.
6. Open the material container. Remove any packing
materials, and inspect for material contamination. If
Do not use a restrictive quick-disconnect. The air
the container has a plastic liner, pull it tightly over
supply pressure must be consistently above the
the sides of the container, and secure the liner in
pressure you set on the main air motor regulator.
place with tape wrapped below the top drum rim.
308930K 17
Setup
8. Open the drum vent valve (R), FIG. 10. Priming Resin Pump
If you have a disposable mixer gun, switch the air
toggle switch (on air control kit) to BYPASS.
1. Place a waste container under the pump bleed valve
(T), located behind the displacement pump outlet,
FIG. 12. Using an adjustable wrench, open the bleed
valve counterclockwise 1/3-1/2 turn.
R
FIG. 10
WARNING
FIG. 11
10. After the ram plate seals contact the drum, adjust
the ram air regulator (D) to about 30-50 psi
(207-345 kPa, 2.1-3.4 bar).
11. When the ram stops and material fills the bleed port
(or air stops bleeding out), close the drum vent valve
(R), FIG. 10.
18 308930K
Setup
5. Make sure the air motor and catalyst feed air shutoff
valves (G and E) are closed, FIG. 13.
P
U
ED
N
LI
S
K
AR
M
AP
C
D
EN
H
IT
W
LE
B
EM
S
AS
AG
FIG. 14
S
G
FIG. 13
308930K 19
Setup
Loading Catalyst Material under the wiper plate, scoop fluid from the center of
the pail to the sides to make the surface concave.
Follow the procedure for the type of supply equipment
being used.
WARNING
EE
RR
FF
FIG. 16
20 308930K
Setup
Pressure Tank
1. Remove the pressure tank lid and any items
shipped inside the tank. Make sure the tank is
clean, or use the liner supplied.
GG
HH
FIG. 17
F
E
FIG. 18
308930K 21
Setup
P
U
ED
N
LI
S
K
AR
M
AP
C
D
EN
H
IT
W
LE
B
EM
S
AS
AG
FIG. 20
FIG. 19
22 308930K
Setup
All Models
8. Fill the catalyst bypass hose. Disconnect the cata-
lyst return hose from the ram plate or pressure tank
return fitting.
CAUTION
The materials will cure after mixing. Purge the mixer,
hose, and gun with clean material before the material
begins to cure.
308930K 23
Operation
Operation
Pressure Relief Procedure
WARNING
h
T
FIG. 24
6. Leave the bypass valve (H) open until you are ready
to dispense again.
24 308930K
Operation
CAUTION
Make sure the catalyst relief valve is operational and J K
free from blockage at all times. See manual 308547. If
the relief valve fails, the overpressure rupture disc
opens and catalyst is diverted to a waste container
mounted on the ram base plate.
7. Adjust the air motor air regulator (S) for the desired
S flow rate.
G
F
E
FIG. 25
308930K 25
Operation
CAUTION
Do not operate the pump with both the catalyst feed
shutoff valve (AG) and the catalyst bypass valve (H) in
the closed position. Doing so will cause excessive pres-
sure to develop in catalyst lines and the safety relief
valve to open. Make sure the catalyst relief valve is
operational and free from blockage at all times. See
valve manual 308547.
P
U
ED
N
LI
S
K
AR
M
AP
C
D
EN
H
IT
W
LE
B
EM
S
AS
AG
FIG. 27
26 308930K
Operation
Hydra-Mate with Disposable Mixer Gun 3. Place the ram lever (C) in the UP position, FIG. 29.
D
C
S
G
KK
FIG. 29
F
E 4. Push and hold the ram separation air button (KK).
308930K 27
Operation
Key:
A Desiccant filter (air dryer)
B Vent drain valve 1
C Pressure Relief Valve
21
D Air shutoff valve
14 Dry air line
16 Fluid outlet shutoff valve
20 Fluid return line
21 Fluid line to metering pump
20 D
38 Fill port cap
14 16
1 Arrow points toward tank
C
38
B
9461A
FIG. 30
28 308930K
Troubleshooting
Troubleshooting
Hydra-Mate Operating Pressures Example (most common):
The Bulldog air motor with the 222639 resin pump
There are three fluid pressure gauges on a typical
and the 222017 slave pump, at a 12.5:1 mix ratio,
Hydra-Mate system. They are mounted on:
has a fluid/air ratio of 27:1. This means that at 100
psi (0.7 MPa, 7 bar) of air, the pumps will generate
• Catalyst slave pump support base
2700 psi (19 MPa, 186 bar). Normal friction losses
• Resin outlet block
with mastic materials will use up 5-15% of that force,
• Catalyst outlet block
resulting in an actual stall pressure of 2300-2565 psi
(16-18 MPa, 159-177 bar).
What the fluid gauges tell you
Catalyst Inlet Gauge A similar King air motor powered unit would have a
fluid/air pressure ratio of 54:1. 50 psi (345 kPa, 3.4
The catalyst slave pump inlet pressure gauge shows bar) of air provides the same results as above.
whether there is sufficient catalyst supply to reliably feed
the slave pump during its intake stroke. • Running: While running, the gauge reads the
flow-induced pressure drop between the gauge and
These double-acting pumps dispense fluid on both the gun outlet. All the motor power is used up by the
strokes, but load only on the stroke when the displace- time the fluid exits the gun. The pressure drop is a
ment rod is pulled out of the cylinder. That means that measure of friction loss caused by hoses, fittings,
during the intake stroke, the fluid loads into the cylinder mixers, gun, and gunning block.
at twice the output rate.
The difference in the gauge reading between the
When the main pump is on the downstroke, the slave stall condition and running is the amount of dynamic
pump is on the loading stroke. Watch the gauge when friction loss from the pump assembly, plus the
the linkage is pulling the pump housing down. The inlet flow-induced pressure drop from the pump lower to
gauge reading will drop while the pump is loading. The the pressure gauge.
gauge should never drop to zero.
Viscosity, temperature, flow rate, and gun setup can
The catalyst supply air pressure should be set high affect the amount of gauge drop when the trigger is
enough to maintain a reliable slave pump feed pressure pulled. On a typical manual gun system, the gauge
but no higher than necessary. drops 100-400 psi (0.7-2.8 MPa, 7-28 bar). On sys-
tems where the motor is piloted with a signal from
Resin Pump Outlet Gauge the gun, there is no significant gauge drop.
The resin pump outlet gauge shows two different condi-
tions, stalled and running.
308930K 29
Troubleshooting
Catalyst Pump Outlet Gauge Check valves near the pump outlets isolate the hoses to
let them serve as momentary surge chambers. This is
The catalyst gauge shows line pressure, but the catalyst
why flow from the gun is smooth during changeover.
pressure is mainly generated as a reaction to resin pres-
sure at the mix manifold.
Abnormal Readings
Catalyst cannot open the check (injector) valve until its Since so many factors affect gauge readings, it is impor-
pressure equals resin pressure at the check valve. tant to know what is normal. Note how your gauges read
Hoses and injector restriction are chosen to naturally when the machine is setup and running a good mix with
balance the pressure drop while running and match the no soft spots. What are the stall pressures and what are
catalyst pressure in the line when stalled. the running pressures for a given inbound air pressure?
How much drop is there on changeover?
Changeovers
If something goes wrong, a change on the gauges can
When the pumps change direction there is a momentary
indicate what the problem is. Note those changes and
change in gauges. In general, the gauges will drop
work through the troubleshooting guide, page 29.
5-15%, then return. However, many factors affect the
actual fluctuation, such as pump selection, fluid charac-
teristics, flow rate, temperature, and length of hoses.
During normal operating conditions, the Hydra-Mate air • The decreased pump outlet pressure may affect the
motor is filled with air almost instantaneously on both pumps’ checking action, and thus mix ratio, resulting
changeovers. in the dispense of what appears to be poorly mixed
material.
However, if the Hydra-Mate air supply is restricted, it can
take significantly longer for air to fill the air motor. To • Changing air pressure changes the compression of
check for this, observe the gauge on the air motor pres- the resin hose and material. This causes an off ratio
sure regulator during both changeovers: condition until pressures stabilize. Equipment air
supply pressure must always stay above the motor
• At the end of each stroke the air pressure will drop regulator setpoint.
abnormally as the air motor begins to fill.
• Once the air motor has filled with air, all air pres-
sures and flow rates will return to normal until the
end of the next stroke.
30 308930K
Troubleshooting
Pump Cavitation During master pump cavitation, the pressure drop may
cause a noticeable reduction in flow rate at the dispense
Under normal operation, the force generated by the gun. Additionally, the interruption in the master pump
Hydra-Mate air motor is absorbed by the master and material output may cause catalyst rich material to dis-
slave pumps. The result is near equal master and slave pense, which may appear as poorly mixed material.
pump outlet pressures.
During slave pump cavitation, the interruption in the
When the master or slave pump outlet pressure drops, slave pump material output may cause resin rich mate-
such as during a pump malfunction, it absorbs less force rial to dispense, which may appear as poorly mixed
than normal from the air motor. This excess force is material. A worn Hydra-Mate linkage can slow the slave
absorbed by the other (non-failing) pump and its outlet pump changeover and thus give the appearance of cavi-
pressure increases. tation.
308930K 31
Troubleshooting
32 308930K
Troubleshooting
308930K 33
Troubleshooting
34 308930K
Troubleshooting
308930K 35
Troubleshooting
Tri-Core Mixer Keep the injector clean. Inspect the housing tip and nee-
dle end for dents or scratches. Lapping the needle to the
Under normal operating conditions, the resin and cata- housing with automotive lapping compound will recondi-
lyst are blended into a uniform mixture by mix elements tion the seat/needle. When reassembling the injector,
contained in three passages in the Tri-Core mixer. tighten the nut 2-2.5 turns after the slack is taken up
Catalyst Injector
36 308930K
Troubleshooting
308930K 37
Parts
Parts
Part No. 953100 & 570312
Part No. 953100
25:1 Bulldog Pump, No. 7 Slave Pump, Configurator Model A-1
Key:
A 1 in. npt(f) Fluid Outlet J Resin Outbound Pressure Gauge
B From Catalyst Metering Pump K Catalyst Outbound Pressure Gauge
C Return to Catalyst Supply L Catalyst Bypass Valve
D Rupture Disc Discharge Hose M Proportioner Air Supply
E From Catalyst Bypass Valve N Catalyst Feed Air Supply
F 3/4 npt(f) Pump Inlet O Ram Air Supply
G To Relief Valve Drain
38 308930K
Parts
1 11 A B
13 15
D E
12 Resin Ratio Check Catalyst Ratio
Valve Detail Check Valve Detail
36
35
2 48
10
21
32
9 40
3, 4 56
37 G 26
5, 7, 18 31
53 47
24
8 30
15 25
33
6
F
21 54
14
Inlet Valve Detail Catalyst Pump Detail Catalyst Outlet Detail
51, 52 29
L
27, 28
49
22, 38, 39 O
23
20
57
58
Slave Linkage Detail
9471A
308930K 39
Parts
Key:
A 1 in. npt(f) Fluid Outlet K Catalyst Outbound Pressure Gauge
B From Catalyst Metering Pump L Catalyst Bypass Valve
C Return to Catalyst Supply M Proportioner Air Supply
D Rupture Disc Discharge Hose N Catalyst Feed Air Supply
E From Catalyst Bypass Valve O Ram Air Supply
F 3/4 npt(f) Pump Inlet
G To Relief Valve Drain
J Resin Outbound Pressure Gauge
40 308930K
Parts
1 62 11 A B
1
13 15
D E
12 Resin Ratio Check Catalyst Ratio
Valve Detail Check Valve Detail
36
35
2 48
10
21
32
9 40
3, 4 56
37 G 26
5, 7, 18 31
53
47
24
8 30
15 25
33
6
F
21 54
14
Inlet Valve Detail Catalyst Pump Detail Catalyst Outlet Detail
22, 38, 39 O
23
20
57
58
Slave Linkage Detail
9472A
308930K 41
Parts
Key:
A To Proportioner
B To Ram
C Air Inlet
A 28
16 26 20
6
13
11
23
32 37
11
2, 3, 4, 8 21
B
24 31
36 15
Ram Control Side View
22
33, 34 27 7 30
10
35 14
17 29
9 19 C
42 308930K
Parts
14 12
6
28b
4 28b 6, 8 25 8
26
30
17
28c
6, 8
8, 19
28a
3, 7, 11
8, 27 6, 8
31 22
308930K 43
Parts
Key:
A 1 in. npt(f) Fluid Outlet
B 1 in. npt(f) Fluid Inlet
C 1/4 npt(f) Fluid Inlet
D 1/4 npt Inlet
E 1/2 npt Outlet
F 3/8 npt(f) Fluid Outlet
28 Resin Check Valve
17 Catalyst Pressure Relief Valve
18 Sample Valves, see manual 309207 for ratio check information
1 Install diaphragm (24) with its protrusion facing down into the
housing (21). Be careful not to damage it.
44 308930K
Parts
17
A 3, 32 12 C 14 30 7 7 31 2 4
4
28 11
5
13
21 13
26 8 3, 32 2 27
20 B
30 29
1
1 24
REF 21
E 6 13 6 10 25
Catalyst Rupture
Disc Detail
2
F
18
19
9463A
308930K 45
Parts
46 308930K
Parts
49 23
35
48
6, 7
4
20
50
28 22 37
1
41 27
24 31
13
36
22 46, 16 10
18 1
47
15 12
43 14
28
40
25
3, 9, 30
33
8 29
45
2
REF 41 REF 50 REF 4 39 26 17 11
REF 1 REF 49
9462A
1 Bleed valve
2 Check valves - arrows point into pail
308930K 47
Parts
33
21 34
7 1 6
16 30
32 31
13 27
9 1
25
24
4
1, 19
2
D 7
20 14 16
C
B 37, 38
1
5
Key: 23, 36
A Desiccant filter (air dryer)
B Vent drain valve 3 15, 39
C Pressure Relief Valve
D Air shutoff valve
5
14 Dry air line 10
16 Fluid outlet shutoff valve 18
20 Fluid return line 11
21 Fluid line to metering pump A
38 Fill port cap
1 Arrow points toward tank
9461A
48 308930K
Parts
11 4 9 8
12
10
6
5 13
7 3
End View 2
9467A
308930K 49
Parts
14 4 9 8
12
13
6 10
5
7 1
3
End View
2
9466A
50 308930K
Parts
16 9, 14, 15 7
5
1 4
9456A
308930K 51
Parts
52 308930K
Parts
1 2
15
3 1 ref. 13
7 16
4 ref. 14
8
6
20
16
21 14
5
12
2 11 9
10
13
9468A
308930K 53
Parts
1 2 20
15
3 1 ref. 13
7 16
4 ref. 14
8
6
20
16
2 5 14
21
12
3 11 9
10
13
54 308930K
Parts
1 2
15
3 1 ref. 13
7 16
4 ref. 14
8
6
20
16
2 5 14
21
12
3 11 9
10
13
9470A
308930K 55
Parts
15
1 2 ref. 13
16
3 1
7 ref. 14
4, 22
8
6
20
16
21 14
5
10
12
2 11 9
10
13
9454A
56 308930K
Parts
15
1 2 ref. 13
16
3 1
7 ref. 14
4, 22
8
6
20
16
2 5 14
21
12
3 11 9
10
13
308930K 57
Parts
15
1 2 ref. 13
16
3 1
7 ref. 14
4, 22
8
6
20
16
2 5 14
21
12
3 11 9
10
13
58 308930K
Parts
308930K 59
Parts
60 308930K
Parts
8 10 12
3 6 11 14
37
Top View of Gun
20
20
37
5 18 9 7 28 or 5 13 17 or 3
16
35 36
16
19
ti16582a
25 5 23
26
4, 5
24
IN
CYL.
27
16 31
16
32
21
34 33
Air Control Logic Detail
9457A
308930K 61
Parts
62 308930K
Parts
8 10 12
3 6 11 14
37
Top View of Gun
20
20
37
5 18 9 7 28 or 5 13 17 or 3
16
35 36
16
19
ti16582a
25 5 23
26
4, 5
24
IN
CYL.
27
16 31
16
32
21
34 33
Air Control Logic Detail
9457A
308930K 63
Parts
64 308930K
Parts
8 10 12
3 6 11 14
37
Top View of Gun
20
20
37
5 18 9 7 28 or 5 13 17 or 3
16
35 36
16
19
ti16582a
25 5 23
26
4, 5
24
IN
CYL.
27
16 31
16
32
21
34 33
Air Control Logic Detail
9457A
308930K 65
Parts
Accessories
66 308930K
Technical Data
Technical Data
Maximum system working pressure . . . . . . . . . . . . . . . . . 3000 psi (21 MPa, 207 bar)
Maximum air motor input pressure . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)
Pump fluid outlet size
Slave Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)
Master Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 in. npt(f)
• Refer to pump Output Charts on pages 13-16 for ratio adjustment and displacement pump part no. informa-
tion.
• For wetted parts information and additional technical data, refer to your separate component manuals.
308930K 67
Graco Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale 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 accordance with Graco’s written
recommendations.
Graco warrants all equipment referenced in this document which is 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
accordance 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 substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or 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 WARRANTY, 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 reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor:
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
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.
Original instructions. This manual contains English. MM 308930
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2002, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 11/2010