Graco SuperCat 23209 Instructions Manual
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Graco SuperCat 23209 Instructions Manual

Graco SuperCat 23209 Instructions Manual

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INSTRUCTIONS
Installation and Service
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
FIXED RATIO, HIGH CAPACITY
SuperCat
5000 psi (34 MPa, 345 bar) Maximum Working Fluid Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Air Pressure
Part No. 232096, Series A, Premier 12 x 12, 2:1 ratio
Part No. 232097, Series A, Premier 9 x 6, 3:1 ratio
Part No. 232098, Series A, Premier 12 x 6, 4:1 ratio
Part Nos. 232713 to 232724, Heated Packages (see page 4)
Includes proportioner control, Premier
two reservoirs, mixing manifold, automatic pressure relief valves, check valves,
fluid filters, pressure gauges and regulators, and Silver Plus
Heated packages include two Vis-con
U.S. Patent Pending
Recognized Component
Conforms to ANSI/UL
standard 2279
110474
Certified to CAN/CSA
22.2 No. E79–1 1–95
EExia II A T4
D
98D.123370
Intrinsically Safe for Hazardous Locations
Class ; Division 1; Group D
GRACO INC. P.O. BOX 1441
Proportioner Package
proportioner pump, President solvent pump,
spray gun.
fluid heaters, plumbing, and feed pump kit 240689.
Model 232721 Heated
4:1 Proportioner Shown
MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
308925
First choice when
quality counts.
This manual contains
changes not included
throughout the contents.
Please see the second
page of this book (page 1A)
for a description of the
revisions and additions.
Rev. B
8787A

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  • Page 1 98D.123370 Model 232721 Heated 4:1 Proportioner Shown Intrinsically Safe for Hazardous Locations Class ; Division 1; Group D 8787A GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 COPYRIGHT 1998, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...
  • Page 2 Instruction Manual-Parts List Changes This page contains a summary of changes or additions that do not appear in the contents of the manual. 308925, Fixed Ratio, High Capacity SuperCat™ Proportioner Package Parts Covered: SuperCat SuperCat Basic CS SuperCat Basic SST 232095 243467 243617...
  • Page 3 New Power Supply (ref. no. 118, page 103 and 104): Part No. 239844 Power Supply is replaced by Part No. 243489 Power Supply, which includes an air regulator and attaching parts. Set the air regulator to 40 psi for SuperCat operation. The new power supply contains the following parts not listed in the manual: 512909 Muffler 114109 Elbow Connector...

  • Page 4: Table Of Contents

    Table of Contents Heated Models ....... . Solvent Usage Reset .
  • Page 5 ......Graco Standard Warranty ....

  • Page 6: Heated Models

    Heated Models Package Part No. Series Proportioner Part No. Ratio Heater Part No. Heater Voltage 232713 232096 (12 x 12) 220523 240V 232714 232096 (12 x 12) 220524 480V 232715 232096 (12 x 12) 237312 200V 232716 232096 (12 x 12) 222307 220V 232717...

  • Page 7: Symbols

    Symbols Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions. or destruction of equipment if you do not follow the instructions.
  • Page 8 Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer. 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.
  • Page 9 This equipment is for professional use only. Read all instruction manuals, 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.

  • Page 10: Component Identification

    204 Fluid Drain Valve Gun Whip Hose, 6 ft (1.83 m)., 1/4 in. (6.35 mm) 207 Fluid Outlet Pressure Gauges Graco Silver Plus Spray Gun 506 Fluid Heater Standard 3 Gun Manifold (out of view behind reservoir) 508 Insulated Fluid Hose (shown)

  • Page 11: Installation

    Installation General Information If moving the proportioner with a forklift, be sure it is securely set on the forklift before lifting it. Reference numbers and letters in parentheses in this text refer to the numbers and letters in the illustrations. If moving the proportioner with a crane, the propor- tioner must be placed in a cage or other sturdy sup- Be sure all accessories are adequately sized and...

  • Page 12: 241157 Heater Kit

    Installation 2. Optional: Install 241157 Heater Kit WARNING FIRE, EXPLOSION, AND ELECTRIC NOTE: Packages 232713 through 232724 are SHOCK HAZARD shipped with the 241157 Heater Kit and two Vis- The Vis-con Heaters must be installed con Fluid Heaters installed. by a qualified electrician in compliance with all state and local codes and regula- tions, to reduce the risk of electric shock or other serious injury during installation...
  • Page 13 Installation Standard Heater Configuration To heat cold material in the reservoirs, set the heaters to the desired temperature, open the Fig. 4 shows the standard heater configuration. In recirculation valves and circulate the fluid using the this configuration, install the heaters on the recir- proportioner pump.

  • Page 14: Installing Additional Heaters

    Contact your Graco distributor for further informa- Spray one batch at a time, then repeat the tion. process.
  • Page 15 Installation b. Option 2, for continuous applications Fill the reservoirs manually. Set the heaters to the when reservoirs are filled manually: In this desired temperature and begin spraying. With this configuration, the maximum working pressure option, continuous spraying is possible. of the proportioner must be derated to 4000 psi (27.6 MPa, 276 bar).
  • Page 16 Installation Option 3, for continuous applications when desired temperature and circulate the fluid using reservoirs are filled manually: Install additional the circulation pumps. When the fluid temperature circulation pumps to create a loop from the reser- in the reservoirs reaches the desired level, begin voirs, through the circulation pumps, through the spraying.

  • Page 17: 240689 Feed Pump Control Kit

    Installation 4. Optional: Install the feed pumps and 5. Optional: Install the 240690 Level Sen- the 240689 Feed Pump Control Kit. sor Kit The optional 240690 Level Sensor Kit includes two level sensors, to add to the two supplied with the NOTE: The 240689 Feed Pump Control Kit is proportioner.

  • Page 18: Relocate The Mix Manifold

    Installation 7. Optional: Remove and relocate the mix manifold. It may be necessary to move the mix manifold (17) closer to the object being sprayed to reduce the length of mixed material fluid hose. This will help reduce material waste and may be necessary when using materials with very short work life.

  • Page 19: Ground The Equipment

    Installation 9. Ground the equipment. Air hoses: use only electrically conductive hoses with a maximum of 500 feet (150 m) combined hose length to ensure grounding continuity. WARNING Fluid hoses: use only electrically conductive fluid FIRE AND EXPLOSION HAZARD hoses. Improper grounding could cause static sparking, which could cause a fire or Air compressor: follow manufacturer’s recom-...

  • Page 20: Fill Pump Throat Packing Nut/Wet Cup

    (K). (610) into the solvent container. Keep the pump throat packing nut/wet cup (K) filled with Graco throat seal liquid (TSL) to help prevent fluid from drying on the displacement rod 610 Solvent Pump Siphon Hose and damaging the pump packings. See Fig. 11.

  • Page 21: Metal Waste Container

    Installation 14. Place a metal waste container (49) Waste Container 228 Beakers under the pressure relief (203) and 203 Automatic Pressure 240 Fluid Tube fluid drain (204) valves. Relief Valve 242 Fluid Tube 204 Fluid Drain Valve WARNING INJECTION HAZARD Fluid emitted from the automatic pressure relief valves and fluid drain valves may be at high pres- sures.

  • Page 22: General Operation

    General Operation Pressure Relief Procedure 5. Hold a metal part of the spray gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure. WARNING 6. Lock the spray gun trigger safety. INJECTION HAZARD 7.

  • Page 23: When To Flush The System

    General Operation When to Flush the System Fluid Heaters WARNING WARNING COMPONENT RUPTURE HAZARD FIRE AND EXPLOSION HAZARD Heat causes fluid to expand. If the To reduce the risk of static sparking and heated fluid is trapped with nowhere to splashing, relieve the pressure, remove expand, it can cause component rupture.
  • Page 24 Notes...

  • Page 25: Control Overview

    Control Overview Modes of Operation Lights Except for the Manual/Spray Mode key, the keypad There are three main modes of operation: light will turn green for the key that is pressed (active function). Manual Mode Spray Mode If an alarm occurs, the lights for that alarm will turn red Setup Mode on the schematic panel.

  • Page 26: System Schematic Panel

    Control Overview System Schematic Panel Setup Mode To switch to Setup Mode, you must first be in Manual Refer to Fig. 18. The System Schematic Panel is a Mode . See page 23. Then touch the key (EE) to the representation of the SuperCat system.
  • Page 27 Control Overview KEY–feed pump A KEY– KEY–Premier pump solvent pump A/B S KEY– feed pump B Light KEY Blinking Green: Volume of Material A usage displayed Constant Green: Feed pump A on. Blinking Green: Volume of Material B usage displayed Constant Green: Feed pump B on.

  • Page 28: Manual Or Spray Mode

    Manual or Spray Mode Using the Manual/Spray Mode To Turn off an Alarm Instructions Press the stop key (1) to turn off all the alarms except To best utilize the following instructions, first read the a Work Life Time Alarm, which requires that the Pre- previous pages of Control Overview, which will give mier pump or solvent pump be turned on to reset the you the basic information needed to understand the...

  • Page 29: Reservoir Low Level Sensor

    Manual or Spray Mode Reservoir Low Level Sensor Low Level Sensor System Schematic Panel The reservoir low level sensor light turns green when B AB the sensor detects fluid. In Spray Mode, the low level sensor light turns red when no fluid is detected and the system shuts down. In Manual Mode, the sensor light turns off when no fluid is detected.

  • Page 30: Cycle Counting And Material Usage

    Manual or Spray Mode Cycle Counting and Material Usage Solvent Usage Reset Cycle counts of the proportioner pump A and B sides To reset the solvent usage totalizer to zero, press key and solvent pump allow the control to keep track of: 2 for five seconds.

  • Page 31: Pressure Sensors

    Manual or Spray Mode Pressure Sensors When key 3 is pressed to read pressure, the key 3 Low Pressure A light will turn green, the schematic light for the pres- Low Pressure B sure Sensor being read will blink, and the pressure reading for that Sensor will display on the keypad.

  • Page 32: Material Usage

    Manual or Spray Mode Material Usage When key 4 is pressed to display the amount of mate- rial used, the key 4 light turns green and the schematic light blinks for the proportioning pump that corresponds to the keypad display. See Fig. 29 and 30. The display will show the amount of material A, materi- al B, or total material (A + B) used since the value was last reset.

  • Page 33: Temperature Limits

    Manual or Spray Mode High and Low Temperature Limits, A or B When key 6 is pressed to display the A or B current Temperature A or B temperature, the key 6 light turns green and the sche- A/B S matic light blinks.

  • Page 34: Work Life Time

    Manual or Spray Mode Work Life Time CAUTION A backup system for tracking how long mixed mate- rial has been in the system is imperative. Do not rely on the work life time alarm alone. When key 7 is pressed to display the remaining work life time, the key 7 light turns green, and the schematic work life time light blinks.

  • Page 35: Setup Mode

    Setup Mode Using the Setup Mode Instructions To best utilize the following setup instructions, first read the sections Entering Setup Mode , Navigating Within Setup Mode , and Saving Changes – Exiting Setup Mode, page 34. These sections will give you the basic information needed to use the Setup Mode.

  • Page 36: Entering Setup Mode

    Setup Mode Entering Setup Mode 1. Make sure you are in Manual Mode (Mode Key 0 light is off). 2. Touch the key (EE) to the setup contacts (TT). See Fig. 36. 3. Level 1 appears when Setup Mode is initially accessed and the Key 2 light turns on.

  • Page 37: Setup Functions

    Setup Functions Solvent Key 2, Level 1 Solvent Pump Cycle Total (non-resettable) Purpose The cycle total is non-resettable. The multiplier keeps track of the total number of cycles the solvent pump has run since the equipment was first started Access Fig.

  • Page 38: Solvent Usage

    Setup Functions Solvent Key 2, Level 2 Solvent Usage Default Setting: 104 cycles/gallon (27.5 cycles/liter) Purpose To set the cycles per gallon/liter for the solvent pump. This allows the control to calculate the usage of solvent. The value is displayed when the solvent key 2 is pressed in Manual or Spray Modes.

  • Page 39: Amount Of Solvent

    Setup Functions Solvent Key 2, Level 3 Amount of Solvent Default Setting: 2 gallons (7.57 liters) Purpose To turn off the solvent pump after the set amount of solvent is supplied. Pressing the solvent pump key (Fig. 43) runs the solvent pump until it supplies the amount of solvent set at this function.

  • Page 40: Select Stored Recipes

    Setup Functions Solvent Key 2, Level 4 Select Stored Recipes Default Setting: 1, 2, 3, or 4 (1:1, 2:1, 3:1, or 4:1 ratio with temperature sensors off), or 5, 6, 7, or 8 (1:1, 2:1, 3:1, or 4:1 ratio with temperature sensors on, feed pumps on, and high level sensors selected) Purpose To select a recipe saved previously.

  • Page 41: Save Recipes

    Setup Functions Solvent Key 2, Level 5 Changing Values Press an arrow key until the number you want to Save Recipes assign the recipe displays. Only unused recipe num- bers will be displayed. Exit setup mode from this function to save the recipe under the selected number Default Setting: 1, 2, 3, or 4 (1:1, 2:1, 3:1, or 4:1 ratio and to run the new recipe.

  • Page 42: High Pressure A Or B

    Setup Functions Pressure Key 3, Level 1 High Pressure A or B Default Setting: 5500 psi (37.4 MPa, 379 bar) Purpose Turns off the Premier pump and sounds an alarm if the system pressure exceeds the high pressure A or B setting.

  • Page 43: Maximum Pressure Differential

    Setup Functions Pressure Key 3, Level 2 Maximum Pressure Differential Default Setting: 2000 psi (14 MPa, 138 bar) Purpose To turn off the system and sound an alarm if the pressure differential between proportioning pumps A and B exceeds the maximum pressure differential setting.

  • Page 44: Peak Pressures Display

    Setup Functions Pressure Key 3, Level 4 A/B S Peak Pressures Display B AB Purpose To help select pressure setup values and to trouble- shoot pressure alarm conditions by displaying the equipment’s peak pressures for Low Pressure A, Low Pressure B, High Pressure A, High Pressure B, and Pressure Differential.

  • Page 45: Low Pressure A Or B (Optional)

    Setup Functions Pressure Key 3, Level 5 Low Pressure A or B (Optional) Default Setting: 5 psi (0.03 MPa, 0.3 bar) Purpose To turn off the system and sound an alarm if the system pressure drops below the low pressure A or B setting.

  • Page 46: Low Pressure Sensor Option

    Setup Functions Pressure Key 3, Level 6 Low Pressure Sensor Option Default Setting: 2, no low pressure sensors Purpose To set the control to monitor for low pressure at the reservoir outlet if the low pressure sensor accessory has been installed. Access Fig.

  • Page 47: Premier Pump Cycle Total (Non-Resettable)

    Setup Functions Material Usage Key 4, Level 1 Premier Pump Cycle Total (non-resettable) Purpose The cycle total is non-resettable. The counter keeps track of the total number of cycles the Premier pump has run since the equipment was first started up. NOTE: The cycle total will reset to 0 if the software is Fig.

  • Page 48: Material B Usage

    Setup Functions Material Usage Key 4, Level 2 Material B Usage Default Setting: see chart below for default settings depending on the pump ratio Purpose To set the cycles per gallon/liter for proportioner side B. This allows the multiplier to calculate the usage of material B.

  • Page 49: Material A Usage

    Setup Functions Material Usage Key 4, Level 3 Material A Usage Default Setting: see chart below for default settings depending on the pump ratio Purpose To set the cycles per gallon/liter for proportioner side A. This allows the control to calculate the usage of material A.

  • Page 50: Feed Pump Alarm Time (Optional)

    Setup Functions Material Usage Key 4, Level 4 Feed Pump Alarm Time (Optional) Default Setting: 1 minute Purpose For use in spray mode with systems using feed pumps. If the feed pumps run longer than the set time, the control will turn off the pumps and sound an alarm.

  • Page 51: Premier Pump Cycle Count (Optional, Non-Resettable)

    Setup Functions Material Usage Key 4, Level 5 Premier Pump Cycle Count (Optional, non-resettable) Purpose For use in systems using feed pumps to keep the reservoirs filled by turning on the feed pumps after the fluid level drops below the reservoir full level sensor and the set number of Premier pump cycles have elapsed.

  • Page 52: Level Sensor Selection

    Setup Functions Material Usage Key 4, Level 6 Level Sensor Selection Default Setting: 1 Purpose To set the control to monitor reservoir low and or full level sensors, and activate feed pumps and alarms if feed pumps are used. The standard system comes with level sensors, installed in the lower reservoir Fig.

  • Page 53: Units Of Measurement

    Setup Functions Target Ratio Key 5, Level 1–4, 6 Keys are currently inactive. Target Ratio Key 5, Level 5 Units of Measurement Default Setting: U.S. Measurement (psi/gallons/ F) Purpose To set the proportioner to count and display accord- Fig. 75 ing to the user’s standard unit of measurement.

  • Page 54: Material A High Temperature Limit

    Setup Functions Temperature Key 6, Level 1 Temperature Key 6, Level 2 Material A Temperature High Limit Material A Temperature Low Limit Default Setting: 120 F (49 C) Default Setting: 80 F (27 C) Purpose Purpose To indicate that material A is over the high limit of its To indicate that material A is under the low limit of its temperature range.

  • Page 55: Material B High Temperature Limit

    Setup Functions Temperature Key 6, Level 3 Temperature Key 6, Level 4 Material B Temperature High Limit Material B Temperature Low Limit Default Setting: 120 F (49 C) Default Setting: 80 F (27 C) Purpose Purpose To indicate that material B is over the high limit of its To indicate that material B is under the low limit of its temperature range.

  • Page 56: Work Life Timer

    Setup Functions Temperature Key 6, Level 5 System Schematic Panel The work life timer light blinks. See Fig. 86. Work Life Timer Changing Values Default Setting: 60 minutes The value should be set based on the work life time of Purpose the material and the time required to spray out the To track the amount of time that has passed since...

  • Page 57: Temperature Sensor (Optional)

    Setup Functions Temperature Key 6, Level 6 Temperature Sensor Option Default Setting: 2, no temperature sensors Purpose To set the control to monitor for high and low temper- ature limits at the reservoir outlet if the temperature sensor accessory has been installed. Access Fig.

  • Page 58: Setting Pressure Alarm Levels

    Setup – Setting Pressure Alarm Levels If the optional low pressure sensors are installed, 1. Select the desired unit of measurement. See page start by setting the value for Low Pressure A or B 20% lower than the peak value recorded. 2.

  • Page 59: Recipe Chart

    Recipe Chart Copy this form to record your recipes. Recipe No. Notes Material Manufacturer Material XX:X Setup Mode Solvent Usage Pressure Material Usage Mix Ratio Temperature Level 1 High Pressure A or B High Limit A ______ psi/MPa/bar ______ F ( C) Level 2 Solvent Pump Maximum Pressure...
  • Page 60 Recipe Chart Copy this form to record your recipes. Recipe No. Notes Material Manufacturer Material XX:X Setup Mode Solvent Usage Pressure Material Usage Mix Ratio Temperature Level 1 High Pressure A or B High Limit A ______ psi/MPa/bar ______ F ( C) Level 2 Solvent Pump Maximum Pressure...

  • Page 61: Troubleshooting

    Troubleshooting WARNING WARNING INJECTION HAZARD ELECTRIC SHOCK HAZARD To reduce the risk of a serious injury, To reduce the risk of electric shock, the follow the Pressure Relief Procedure equipment must only be serviced by on page 20 before checking or servicing trained, qualified personnel.

  • Page 62: Fluid Path And Sensor Schematic (Heated Systems)

    Troubleshooting WARNING WARNING INJECTION HAZARD ELECTRIC SHOCK HAZARD To reduce the risk of a serious injury, To reduce the risk of electric shock, the follow the Pressure Relief Procedure equipment must only be serviced by on page 20 before checking or servicing trained, qualified personnel.

  • Page 63: Level Sensors

    Have the following items available before you begin Voltmeter that is capable of reading resistance and troubleshooting. dc voltage. Small standard screwdriver SuperCat system binder (collection of manuals and diagrams in a three-ring binder, supplied by Graco) Level Sensors Problem Operating Condition Cause/Solution Level Sensor Alarm...

  • Page 64: Feed Pumps

    Troubleshooting Feed Pumps Problem Operating Condition Cause/Solution Feed pump does not run In spray or manual mode, schematic Check air regulator setting. Adjust feed pump light is on setting as needed. Check feed pump setup. See below. Check air solenoids. See page 71. If in spray mode, check material usage display.

  • Page 65: High Pressure Sensors

    Troubleshooting High Pressure Sensors Problem Operating Condition Cause/Solution High pressure alarm In spray or manual mode Check valve positions against posi- tions shown in Operation Manual 308875 for current operation. Correct the settings as needed. Check the high pressure A or B set- ting.

  • Page 66: Low Pressure Sensors

    Troubleshooting Low Pressure Sensors Problem Operating Condition Cause/Solution Clean reservoir fluid filters. See Care Low pressure alarm, reservoir In spray mode of the System, page 75. fluid filters are blocked Low pressure alarm, reservoir In spray mode Check low pressure sensor connec- fluid filters are clear tions.

  • Page 67: Temperature Limit Sensors

    Troubleshooting Temperature Limit Sensors Problem Operating Condition Cause/Solution Temperature Limit Sensor Alarm Fluid temperature is above high limit Verify that the temperature sensor or below low limit, schematic sensor option was selected correctly. See light is red. Setup, page 55. Check the sensor wiring connections.

  • Page 68: Premier Pump

    Troubleshooting Premier Pump Problem Operating Condition Cause/Solution Pump does not cycle, no fluid In manual mode, Premier pump key Check pump air regulator setting. pressure developed held down, schematic Premier pump light on Make sure pump air ball valve is open.

  • Page 69: Pump Lowers

    Troubleshooting Pump Lowers PROBLEM CAUSE SOLUTION System will not run or Air pressure or air volume Increase air pressure. Check air compressor and air stops while running. is too low. supply filters, regulator, lubricator valves, and other com- ponents for blockages and restrictions. Be sure that air supply components are sized properly.
  • Page 70 Troubleshooting 5. With the main air valve closed, remove the screws WARNING (469) and guard (424) from the side of the propor- tioner. INJECTION HAZARD This system can produce very high fluid 6. Unscrew the connecting rod nut (361) from the pressure.
  • Page 71 Troubleshooting Pump Lowers 361, 381 361, 381 Fig. 90...
  • Page 72 Troubleshooting Pump Lowers Output pressure of proportioning pump A or B is low on the upstroke WARNING Check if the piston valve is stuck open, or if the piston packings are worn. Clear the piston valve; INJECTION HAZARD replace the packings. See your separate pump To reduce the risk of a serious injury, manual.

  • Page 73: Solvent Pump

    Troubleshooting Solvent Pump Problem Operating Condition Cause/Solution Pump does not run In spray or manual mode, schematic Check pump air regulator setting. solvent pump light on Make sure pump air ball valve is open. Check solvent pump air solenoid. See below.

  • Page 74: Material Usage Display Check

    Troubleshooting Material Usage Display Check (pump cycle counter) Problem Operating Condition Cause/Solution Premier or solvent pump usage In manual or spray mode Visually check wire connections. display value does not change Check the resistance across the sensor, while moving a strong mag- net in front of the sensor.

  • Page 75: Electronic Control Check

    Troubleshooting Electronic Control Check Problem Operating Condition Cause/Solution Keypad display and schematic Open system air supply (red handle blank ball valve). Check air supply pressure and volume. Clean main air filter. Clean power supply filter. Replace power supply. See Service, page 92.
  • Page 76 Troubleshooting KEYPAD KEY AND LIGHT CONTINUITY CHECKS Continuity Check Green Light Red Light Mode Key Light Pin 1 and 18 Pin 2 and 18 Stop Key Light Pin 3 and 18 Pin 4 and 18 Solvent Usage Key Light Pin 5 and 18 Pin 6 and 18 Pressure Key Light Pin 7 and 18...

  • Page 77: Care Of The System

    Care of the System 6. Clean the filter element (54e) and the filter bowl WARNING (54a) with compatible solvent. INJECTION HAZARD 7. Reassemble the filters. Be sure the lips of the To reduce the risk of serious injury, u-cup (54d) face up. follow the Pressure Relief Procedure on page 20 whenever you are instructed 8.

  • Page 78: Clean The Fluid Outlet Filters

    Care of the System Clean the Fluid Outlet Filters Agitator Care 1. Shut off the agitator air control valve (D). Discon- Check the high pressure fluid outlet filters (202) nect the air line from the agitator. weekly. See Fig. 94. 2.

  • Page 79: Clean The Static Mixer

    (424, 446) from the sides of the proportioner. See Fig. 98. 2. Remove the hose (35) from the static mixer (G). 4. The wet cups should be 1/3 full of Graco Throat 3. Unscrew the static mixer (G) from the mix manifold Seal Liquid (TSL) or compatible solvent.

  • Page 80: Bearing Lubrication

    The lubrica- lubricators. One to two drops per minute is a common tion interval is every six months in a single shift opera- rate. Use Graco motor oil, Part No. 202659. Always tion. relieve the system pressure before removing the lubricator bowl for any reason.

  • Page 81: Service

    Hardware or Software Updates operating. WARNING Check with your Graco distributor periodically to see if hardware or software updates are available. ELECTRIC SHOCK HAZARD To reduce the risk of electric shock, the...

  • Page 82: Removing Displacement Pumps A And B

    196–210 N.m (145–155 ft-lb). 5. With the main air valve turned off, remove the screws (469) and the two guards (424,446) from 7. Fill the wet cup 1/3 full with Graco Throat Seal the sides of the proportioner. Lubricant or compatible solvent.
  • Page 83 Service 361, 381 361, 381 Fig. 99...

  • Page 84: Removing The Premier Air Motor

    Service Removing the Premier Air Motor 3. Use an overhead hoist to position the air motor on the frame in the same orientation as noted in step 5 of disconnecting the air motor (see the CAU- CAUTION TION in the preceding removal procedure). Use an overhead hoist when lifting, moving or dis- 4.

  • Page 85: Replacing The Bearings

    7. You should now be able to slide the bearings (497) off of the shaft ends. Inject grease 8. Replace the bearings only with identical Graco replacement parts. Pack the bearings in Industrial Grade 1, Heavy Duty, Extreme Pressure, Lithium Soap Grease, Graco Part Number 110293 or Fig.

  • Page 86: Removing The Solvent Pump

    Service Removing the Solvent Pump for Service 1. Stop the pump at the bottom of its stroke. 2. Follow the Pressure Relief Procedure on page 20. 3. Disconnect the air line from the solvent pump (89). 4. Refer to the CAUTION on page 79. Label the solvent pump (89), suction kit (610), and fluid hose (59) with white tape, for reference when reassem- bling.

  • Page 87: Removing The Mix Manifold

    Service Removing the Mix Manifold for Service Gauge Port Gauge Port 1. Flush the mix manifold, using the solvent pump, as frequently during the day as necessary to avoid exceeding the work-life limit of the material being pumped. 2. Clean the static mixer weekly. Refer to page 77. 3.

  • Page 88: Blinking Or Blank Display

    Service 5. Disconnect the wire harnesses from the two circuit WARNING board connectors. ELECTRIC SHOCK HAZARD 6. Remove the four screws (125f) and remove the To reduce the risk of electric shock, the circuit board cover (125b). air to the air driven power supply must be shut off before servicing the control.
  • Page 89 Service Replacing the Circuit Board 16. Cut the wire ties holding the cable to the propor- tioner. Remove the cable from the wiring conduit. 11. Unscrew the six hex standoffs (125d), and remove the circuit board (125c). See Fig. 105. Reassembly 12.

  • Page 90: Replacing The Solenoid Valves

    Service 1. Follow the Pressure Relief Procedure on page 20. WARNING 2. Turn off the air to the control. ELECTRIC SHOCK HAZARD To reduce the risk of electric shock, the 3. Remove the top cover (25). air to the air driven power supply must be shut off before servicing the control.

  • Page 91: Replacing The Sensors

    Service Replacing the Sensors Temperature Limit Sensors 1. Drain the reservoirs completely. High and Low Level Sensors 1. Follow the Pressure Relief Procedure on page 20. 2. Disconnect the level sensor assembly (513) con- nector from its mating connector (CA). 2.
  • Page 92 Service Replacing the Sensors (continued) Low Pressure Sensor (Optional) 1. Follow the Pressure Relief Procedure on page 20. High Pressure Sensors 2. Close the reservoir ball valve (56). See Fig. 110. 1. Follow the Pressure Relief Procedure on page 20. 3.
  • Page 93 Service Replacing the Sensors (continued) Proportioning Pump Cycle Counter 1. Follow the Pressure Relief Procedure on page 20. Solvent Pump Cycle Counter 2. Disconnect the cycle counter sensor (465) from its 1. Follow the Pressure Relief Procedure on page 20. mating connector.

  • Page 94: Power Supply Turbine Alternator Service

    Service Power Supply Turbine Alternator Service 13. Push the alternator (118g) into the housing (a.). NOTE: Replace turbine bearings after 2000 hours of 14. Connect the 3-wire connector (c.) to the circuit operation. Part No. 223688 Turbine Alternator Repair board (118c). Kit is available.
  • Page 95 Notes...

  • Page 96: Parts

    Parts Heated Package Assemblies 232713 to 232724 518, 519 Part of the standard proportioner . See page 96. 8681A...
  • Page 97 Parts Heated Package Assemblies 232713 to 232724 Part No. Description Qty. Part No. Description Qty. 240949 FRAME, heater 114757 TEE; 1/2 npt(m) 194138 SUPPORT, frame, heater 166866 ELBOW, street; 1/4 npt (m x f) 240689 KIT, feed pump; not shown; 114759 CHECK VALVE;...

  • Page 98: Supercat Proportioner

    Parts SuperCat Proportioner, Fixed Ratio Part No. 232096; 12 x 12, 2:1 Part No. 232097; 9 x 6, 3:1 Part No. 232098; 12 x 6, 4:1 8786A...
  • Page 99 Parts 8337A...
  • Page 100 Parts SuperCat Proportioner, Fixed Ratio Ref. Part No. Description Qty. Part No. 232096; 12 x 12, 2:1 114185 SCREW, cap, button head; not shown Part No. 232097; 9 x 6, 3:1 105468 SCREW, cap, hex head; not shown Part No. 232098; 12 x 6, 4:1 112117 SCREW, cap, hex head 108050...
  • Page 101 Parts SuperCat Proportioner, Fixed Ratio Ref. Part No. Description Qty. Part No. 232096; 12 x 12, 2:1 112190 STRAP, wrist grounding; not shown Part No. 232097; 9 x 6, 3:1 240634 HOSE, coupled with sani- PTFE tary fittings; Part No. 232098; 12 x 6, 4:1 114475 BUSHING, pipe;...
  • Page 102 Parts Detail of Mix Manifold (1 17) 22, 23 (see 35 (Ref.) list on page 109) 8344A–part Premier Pump Assembly (8) Parts list on page 101...

  • Page 103: Premier Pump Assembly

    Parts Item 8: Premier Proportioner Assembly 390, 391 381, 361 361, Ref. Part No. Description Qty. Ref. Part No. Description Qty. – FRAME ASSEMBLY; see 180233 LABEL, warning page 108 for parts 626125 ROD, tie 552215 BUSHING, 2” x 1.5” 186925 NUT, coupling 552216...

  • Page 104: Electonic Pneumatic Control

    Parts Item 18: Electonic Pneumatic Control Assembly 114 (Ref.) * Refer to parts list on page 98. 8785A...
  • Page 105 Parts Item 18: Electronic Pneumatic Control Assembly Ref. Part No. Description Qty. Ref. Part No. Description Qty. 193273 HOUSING, control box 125f 114185 SCREW, cap, button hd; 193277 COVER, control box 114185 SCREW, cap, button hd; M4 125g 240432 KEYPAD 113286 VALVE, air relief;...
  • Page 106 Parts Item 18: Electonic Pneumatic Control Assembly Detail of Power Supply (118) Detail of Access Door (125) 118h 125b 125c 118a 118c 125f 118f 118d 118b 118g 125d 118j Ref. 118b 118k 125g 125a 118e 125e 125h 8324A 7499A–part...

  • Page 107: Solvent Pump Assembly

    Parts Item 89: Solvent Pump Assembly Ref. Part No. Description Qty. 192767 BRACKET, adapter, front 240445 PUMP, solvent, 46:1 Presi- PTFE dent; with packings; see Manual 307619 for parts 192768 BRACKET, adapter, rear 100469 SCREW, cap 100132 WASHER, lock 100307 NUT, hex 193465 SWITCH ASSY., reed...

  • Page 108: Fluid Valve Control Assembly

    Parts Item 34: Fluid Valve Control Assembly 8339A...
  • Page 109 Parts Item 34: Fluid Valve Control Assembly Ref. Part No. Description Qty. Ref. Part No. Description Qty. 114431 CONSOLE 222200 VALVE, fluid flow control; see manual 307892 240183 FILTER, fluid; see manual 551390 BEAKER 307273 for parts 237074 VALVE, relief, automatic; 193179 COLLAR see manual 308547 for...

  • Page 110: Frame Assembly

    Parts Item 301: Frame Assembly 403 (back) 407, 414 (Ref) 458, 459 440, 405 419, 420, 463 413 (Ref)
  • Page 111 Parts Item 301: Frame Assembly Ref. Part No. Description Qty. Ref. Part No. Description Qty. 570325 STAND 626438 PLATE, top 626443 COVER, back right 626439 PLATE, bottom 626449 COVER, front right 551290 SCREW, cap, hex head; M16 x 80 mm 101390 WASHER, lock, internal 626469...

  • Page 112: Dimensions

    Dimensions 74 in. (1880 mm) 42 in. (1067 mm) 66 in. (1676 mm) 8787A...

  • Page 113: Technical Data

    98.8 dBa NOTE: See the individual component manuals listed on page 79 for additional technical data. * Dependent on application. For more detailed information on viscosities, flow rates, or mixing ratios, consult your Graco repr e - sentative. Sound levels include both agitators. Tested per ISO 3744–1981...

  • Page 114: Graco Standard Warranty

    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 sub- stitution of non–Graco component parts.

This manual is also suitable for:

Supercat 232713Supercat 23272

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