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Installation and Operation of Model 8900 Variable Ratio
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Graco Inc.-EAS P.O. BOX 1441 Minneapolis MN55440/Phone (612)379-3700/Fax: (612)378-3541
Engineered
Application
Solutions
TABLE of CONTENTS
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Summary of Contents for Graco 8900
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Page 1: Table Of Contents
Engineered Application Solutions Installation and Operation of Model 8900 Variable Ratio TABLE of CONTENTS Safety Warnings Page 2 Preliminary Installation Instructions Page 7 Material Supply Pumps, Loading, Etc. Page 9 Filling the Meter with Material Page 10 Ratio Adjustment Page 11... -
Page 2: Safety Warnings
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS. Read and understand all instruction manuals before operating equipment. MOVING PARTS HAZARD FLUID INJECTION HAZARD KEEP HANDS AND FINGERS AWAY FROM General Safety PRIMING PISTON DURING This equipment conducts fluid at very high OPERATION AND WHENEVER A PUMP IS pressures. - Page 3 SYSTEM SAFETY DEVICES GUN TIP/NOZZLE SAFETY Be sure all system safety devices are Use extreme caution when cleaning or operating properly before each use. Do not changing dispense gun tips/nozzles. If the remove or modify any part of the system; this tip/nozzle clogs while spraying/dispensing, can cause a malfunction and result in serious engage the gun safety latch immediately.
- Page 4 DO the inner tube and cover of the hose. NOT exceed the maximum working pressure NOT expose Graco hoses to temperatures of any component or accessory used in the above 82°C (180°F) or below -40°C (-40°F) system.
- Page 5 HOSE GROUNDING CONTINUITY GROUNDING FOR PAINT CIRCULATION PAINT CIRCULATION SYSTEMS SYSTEMS Proper hose grounding continuity is essential To reduce the risk of static sparking, ground to maintaining a grounded spray system. the pump, object being sprayed, and all other Check the electrical resistance of your air and spray equipment used or located in the spray fluid hoses at least once a week.
- Page 6 FLUSHING SAFETY OVERHEATED MATERIAL IS DANGEROUS! Do not exceed the maximum temperature Before flushing a spray system, be sure the recommended by the material supplier. Turn entire system and flushing pails are properly off the electricity if the material exceed the maximum temperature.
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Page 7: Preliminary Installation Instructions
Installation and Operation of Model 8900 VR PRELIMINARY INSTALLATION INSTRUCTIONS Remove unit from crate and inspect for shipping damage. If any damage is found, notify the carrier immediately. You are responsible for filling any claims directly with the carrier. Locate machine in position on a level floor in a well ventilated area with access to air power. - Page 8 Installation and Operation of Model 8900 VR OPTIONAL Base Purge Ball Valve; Used to force mixed material from mixer with base only material prior to shutdown. Base purge ball valve is located near inlet to mixer. When open, this valve allows base material only to be pumped directly form the pump to the mixer (bypassing the meter).
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Page 9: Material Supply Pumps, Loading, Etc
Installation and Operation of Model 8900 VR MATERIAL SUPPLY PUMPS: LOADING, PRIMING, AND AIR BLEED Note: Material hoses from pump to meter inlet should not be connected to meter at this point. If hoses are connected to meter, disconnect. supply hoses to pumps should all be connected; note keyed numbers on hose and inlet for proper installation. -
Page 10: Filling The Meter With Material
Installation and Operation of Model 8900 VR FILLING THE METER WITH MATERIAL Air Powered Dynamic Mixer; separate spool valve from mixer (using wing nut) and locate exposed cone checks over waste container. Place dispense actuator lever in DISPENSE position. Connect both base and catalyst supply hoses from pumps to meter inlet;... -
Page 11: Ratio Adjustment
Installation and Operation of Model 8900 VR RATIO ADJUSTMENT FOR MODEL 8900VR The ratio of this unit is produced in part by the difference in the area of the metering cylinders and in part by the position of the adjustable fulcrum point in the Unibar linkage assembly. -
Page 12: Ratio Adjustment Calculation
Installation and Operation of Model 8900 VR RATIO ADJUSTMENT CALCULATION STEP 1: Determine Required Linkage Ratio Required Mix Ratio By Volume (X:1) Required Linkage Ratio (Z:1) Selected Meter Piston Ratio (Y:1) (400 cyl/80 cyl = 5:1) Mix Ratio By Volume is computed as 1000 parts base divided by the parts of catalyst, i.e., 80 part catalyst per 1000 parts base - 1000/80=12.5:1 ratio (12.5... -
Page 13: Adjusting The Ratio
Installation and Operation of Model 8900 VR ADJUSTING THE RATIO Remove the spool valve and cone check assembly from the mixer. With the unit actuated (pull actuator lever), allow material to flow from the cone checks (locate over waste container). -
Page 14: Establish Meter Flow Rate & Pressure
Installation and Operation of Model 8900 VR ESTABLISH METER FLOW RATES AND BALANCED PRESSURES The flow rate for the meter is determined by the pressure of the base and catalyst pump. The air pressure on the base pump will generally affect the amount of flow coming from the material outlet. -
Page 15: General Ratio Check Procedure
Checking the ratio allows the user to take samples of the metered material to insure that the equipment is metering properly. On the model 8900, the ratio check is taken by removing the spool valve and taking the material samples from the spool valve cone check. - Page 16 Installation and Operation of Model 8900 VR Compare the weight ratio obtained to the desired weight ratio. Repeat to obtain several successful ratio checks. If not metering on ratio, see troubleshooting guide later this section EXAMPLE CONVERSION FORMULA: PARTS BY VOLUME (PBV) TO PARTS BY WEIGHT (BPW)
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Page 17: Initial Start Up Procedure
Installation and Operation of Model 8900 VR INITIAL START UP PROCEDURES Dynamic Air Powered Mixer: Air to system (main air) must be ON (black knob out). Air to mixer OFF. Mixer Pre-Start: Open one outlet on cartridge filler; open ball valve to dynamic mixer air motor. -
Page 18: Optional Base Purge Operation
Installation and Operation of Model 8900 VR OPTIONAL BASE PURGE OPERATION Dynamic Mixer Following the end of the dispensing cycle, it is necessary to BASE PURGE the mixer to prevent curing of any mixed material in the mixer. With the mixer motor ON and one of the cartridge fill outlets open, situate a waste container under the cartridge fill outlet. -
Page 19: Optional Solvent Flushing Of System
Installation and Operation of Model 8900 VR SOLVENT FLUSHING OF SYSTEM (Optional) Push black knob on main air control IN to shut machine off. Open ratio check valves to bleed any trapped pressure from system; close valves. situate dispensing gun or outlet over waste container with the gun trigger or outlet fixed open. -
Page 20: Daily Start Up Operations
Installation and Operation of Model 8900 VR DAILY START UP OPERATIONS Perform daily maintenance operations including: Check oil level in main air lubricator Drain any water form filter in main air line iii) Tighten pump packing nuts daily for the first week; tighten weekly thereafter. - Page 21 Installation and Operation of Model 8900 VR A fold test to make certain that you are getting a good mix is recommended. To take a fold test, take a piece of paper about 2’ long and dispense a bead of material ready for production onto the paper.
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Page 22: General Troubleshooting Guide
Installation and Operation of Model 8900 VR GENERAL TROUBLESHOOTING GUIDE Pumps: Cavitating pump, fast cycle, little or no output indicates: Air is trapped in the pump, rebleed pump. Pump strokes evenly on up or down stroke but fast and uneven on other... - Page 23 Installation and Operation of Model 8900 VR Elevator (see also troubleshooting guide on elevator service sheet located with pumps) Failure to Move Up or Down: Lack of air pressure, check air supply. Failure of piston seals in elevator, replace. Broken or damaged air line to top or bottom of elevator;...
- Page 24 Installation and Operation of Model 8900 VR iii) Check for leakage in the meter seals and cups. Substantial leakage indicates that material is bypassing rather than flowing through the meter. Generally, this situation can be diagnosed by incorrect ratio check and reduced material flow rates.
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Page 25: Preventative Maintenance
Installation and Operation of Model 8900 VR PREVENTATIVE MAINTENANCE RECOMMENDATIONS Air Supply: Oil level in main air line lubricator should be checked daily and refilled when required with SAE 10W non-detergent oil. Adjust to dispense 1 drop per minute during operation.