Instructions Parts HYDRA-CATR VARIABLE RATIO Proportioning Pumps 309024C *Includes Automatic Pressure Relief Valves, Check Valves, Pressure Gauges and Regulators Basic Operation for Use with Configured Models Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. WARNING Plural Component Materials Hazard Graco Inc.
Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ratio Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Determining the Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Set the Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Calculate the Ratio Setting . . . . . . . . . . . . . . . . . . . . .
Warnings Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions. WARNING EQUIPMENT MISUSE HAZARD INSTRUCTIONS Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in serious injury. This equipment is for professional use only.
WARNING SKIN INJECTION HAZARD Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause serious injury. Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medical surgical treatment. Do not point the gun/valve at anyone or at any part of the body.
WARNING MOVING PARTS HAZARD Moving parts can pinch fingers. Keep clear of all moving parts when starting or operating the equipment. TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed. Know the specific hazards of the fluid you are using. Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.
Typical Installation NOTE: When pressure feeding the proportioning pump, mount fluid pressure gauges (J) at the proportioning pump inlets to monitor proper adjustment of the feed pump pressures. Never exceed 400 psi on the inbound fluid pressure and never exceed 25% of the Hydra-Cat pump outbound fluid pressure on the feed supply. About Typical Installations The typical installations shown below and on page 7 are only guidelines to setting up a complete VRHC system.
KEY A B C D E F G H J K P R S U V W Y Hydraulic Pump Mounting Stand Hydraulic Supply Line Hydraulic Return Line Drain Line (from pressure reducing valve) Pressure Gauge Flow Control Valve Pressure Reducing Valve Accumulator Feed Pumps Hydraulic Supply Line Shutoff Valve Hydraulic Return Line Shutoff Valve Hydraulic Return Line Filter Hydraulic Power Supply Fluid Hose Fluid Supply Line Pump Ground Wire (required) R Y P A F H D K K J U B G E C V S W 9433A Fig.
Installation NOTE: Reference numbers and letters in the text refer to Figures 1 to 18. Location Sit the proportioner on a flat floor positioner. Connect the Solvent Flush Supply Line Remove the safety panels (38,39,40). See Fig. 4 on page 10. Connect a grounded fluid hose (X) from the solvent flush pump to the 3/8 npt solvent flush inlet (N) of the mixer manifold. Connect the Fluid Supply Lines Connect grounded fluid hoses to the 3/4 npt(f) inlet filter fittings (R,T).
Installation 2. Air and fluid hoses: use only electrically conductive hoses. Grounding WARNING FIRE AND EXPLOSION HAZARD Before operating the pump, ground the system as explained below. Also read the section FIRE AND EXPLOSION HAZARD on page 4. 1. Pump: use the ground wire and clamp (supplied). See Fig. 3. Loosen the grounding lug locknut (W) and washer (X). Insert one end of the ground wire (Y) into the slot in lug (Z) and tighten the locknut securely.
Ratio Adjustment Understanding the terms used with the Variable Ratio Hydra-Cat (VRHC) System, how it functions, and how to find and set the correct ratio(s) for your application, is the key to easier, more versatile operation of your proportioning system. The secondary pump (124) is on the opposite end of the lever arm (49). It usually pumps the catalyst. One or two secondary pumps may be used: one for pumping catalyst and the other for reducer injection.
Determining the Ratio Determine your system conditions If these are your conditions – one primary pump, one secondary pump, fluids are ready-to-spray viscosity – set the ratio as explained under Setting the Secondary Pump(s) on page 14. If these are your conditions – one primary pump and one secondary pump, fluids are NOT ready-to-spray viscosity – the ratio must be determined after the reducer is added to the base, as instructed in Procedure 1.
Set the Ratio Fig. 5 shows the relationship between the primary pump and the secondary pump. 118 4 20% 4 91% 100% 4 To set the secondary pump on a standard VRHC System with only two pumps, refer to Setting the Secondary Pump(s) on page 14. HH To set the secondary pump on a non-standard VRHC System or for an additional secondary pump, refer to Calculate the Ratio Setting, on page 13. NOTE: The (91) index setting provides equal primary and secondary pump stroke lengths. 100 is 1.
Calculate the Ratio Setting In this example, A 5:1 ratio of base to catalyst is required. The base/primary pump Model (e.g. 221074); effective area is 0.470 in. The catalyst/secondary pump Model (e.g. 221026); effective area is 0.278 in. 2. To make sure the index setting does not exceed the secondary pump’s maximum stroke length: a. Multiply the index setting by 0.044 (a constant number). 30.8 x 0.044 1.355 catalyst pump setting constant catalyst pump stroke length 1.
Setting the Secondary Pump(s) The numbers of the pump settings, calculated from the procedures in the section, Calculate the Ratio Setting, correspond to the scale numbers on the lever arm (49) of the VRHC. See Fig. 6. 30 26 16 49 WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 15. 1. Relieve the pressure. 2. Flush the unit as instructed on page 16 before setting the pump. 3. Remove the safety panel (39).
Operation Pressure Relief Procedure WARNING 2. Close the bleed-type master air valve (required in your system). 3. Unlock the gun/valve trigger safety. SKIN INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying/dispensing accidentally. Fluid under high pressure can be injected through the skin and cause serious injury.
Operation The pumps, mixer manifold and other components were tested with lightweight oil at the factory. Before operating the pump, thoroughly flush the VRHC to prevent contamination of the fluids. Starting the Pump NOTE: To open the mixer manifold (120), put the handle in the down position. To close the mixer manifold, put the handle in the up position. See Fig. 7. System Flushing NOTE: Flush the mixer, hose and gun/valve often enough to prevent fluid from reacting or curing in them.
Operation 46 NOTE: To open the mixer manifold (120), put the handle in the down position. To close the mixer manifold, put the handle in the up position. See Fig. 7 on page 16. 49 30 EE Standard Operating Flushing 120 1. Use the solvent valves to flush contaminants and mixed fluids from the mixer manifold, hose and gun/valve. Follow the procedure below. a. Start the solvent pump. Close the mixer manifold. 39 40 119 b. Open one of the solvent valves (EE). c.
Troubleshooting Troubleshooting Techniques Because the pumps are mechanically linked, the action of one pump can affect the readings of the second pump. Therefore, the key to successful troubleshooting is to be sure to isolate the problem. For example, the secondary pump pressure, as read on the gauge, is low and sluggish during pump changeover. The most likely problem is a binding primary pump.
Troubleshooting Problem System won’t run or stops while r nning running Cause Solution Air pressure or volume too low Increase, check air compressor. Closed or restricted air line or air valve Open or clean as required. Fluid valves closed Open fluid valves. Clogged fluid hose Replace fluid hose. Air motor worn or damaged Service air motor; see manual 306982. Displacement pump stuck Service displacement pump. See manuals listed in the chart on page 18.
Service Required Service Tools Tool Air Lubrication (Air Operated Motors Only) Use for 3/32”–90 or T-handle hex key All setscrews 3/4” open end wrench Clamp bolts and fluid hose on pump outlet 1” open end wrench Locknuts on capscrews 9/16” open end wrench Tie rod nuts 1/2” open end wrench Loosening tie rods from motor base 1–1/8” open end wrench Pivot bearing locknuts Adjustable open end wrench Tightening connecting rod to pumps Needle nose pliers Bending and pulling cotter pins Medium sl
Service Removing the Lever Arm from the VRHC Frame WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 15. 11. Remove the punch and lift the lever arm (49) off the VRHC frame. 12. Loosen the two pivot bearing locknuts (2) and turn the bearings (15) out of the housing (122). The bearings should be only hand tight.
Service Determining Which Pin and/or Bearing is Worn Removing the Secondary Pump and/or the Bearings and Pins 1. Disassemble the VRHC. After the pins and bearings are removed, wipe them off with a clean rag. 1. Flush the entire system with a compatible solvent. 2. Visually inspect the pins for scoring, lines, grooves and scratches on the area in contact with the bearing. Then feel the surface of the pin for rough areas or a difference in size.
Service NOTE: Refer to Fig. 14 for steps 4 to 10. 4. Push down on the lever arm (49) until the wrench flats (KK) on the secondary pump (124) are just above the wet-cup (LL). Remove the ratio index clamp capscrews (16a) and the index clamp (30). d. Raise the VRHC lower frame (50) and remove the support (31b). e. Gently tap the support pin (34b) out with a hammer and punch. f. NOTE: Some fluid will drip from the pump when you are removing the ratio index clamp. Replace the pin and bearing. 16a 5.
Service Replacing the Secondary Pump and/or the Bearings and Pins NOTE: Refer to Fig. 14 for Steps 1 to 3. 1. If only the secondary pump is being replaced: a. Screw the secondary pump (124) into the inlet manifold (32). The manifold must face the end of the VRHC as shown in Fig. 14. If it does not, rotate the secondary displacement pump until it does, and tighten the locknut (3) against the inlet manifold. Torque the locknut to 60 ft-lb (81 N.m). b.
Service Removing the Primary Pump and/or the Lower Bearing and Pin 1. Flush the entire system with a compatible solvent. 118 WARNING 121 To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 15. 102c 2. Relieve the pressure. 3. Remove the safety panels (39,40). Disconnect the inlet and outlet hoses on the primary displacement pump (123). NOTE: Refer to Fig. 15 for Steps 4 to 6. 116 103 4.
Service NOTE: If only the motor needs repair, follow the instructions in the appropriate manual. NOTE: Refer to Fig. 16 for Steps 7 to 15. 11. If removing the pump only, remove it from the manifold (32). If the primary pump needs repair, follow the instructions in the separate pump manual. 7. Remove the lower cotter pin (102d) from the connecting rod (121) (if the pump has one) and loosen the two setscrews (59).
Service Replacing the Primary Pump and/or Bearing and Pins NOTE: Refer to Fig. 17 for Steps 1 to 9 except where noted. 1. Screw the displacement pump (123) into the inlet manifold (32) so the outlet is facing the back. 2. Screw the connecting rod (121) onto the primary displacement pump until the cotter pin holes line up. Install the cotter pin (102d) if the pump has one; if not, bottom out the connecting rod on the displacement pump. 7.
Service 9. If replacing the lower bearing (14d) and pin (35d): a. Thread the locknut (3) all the way onto the bearing. b. Screw the inlet manifold (32) onto the bearing twelve turns and tighten the locknut up to the inlet manifold. Torque to 60 ft-lb (81 N.m). c. Lubricate the support pin (35d) with Gear Reducer Oil (43). Install the pin with the countersinks facing up, into one side of the frame base (50). Place one nylon spacer (27d) on the end of the support pin. d.
Service 35 1 30 16 17 15 59 26.125” (664 mm) 31 2 2 35d 15 124 33 27d 32 121 50 50 123 Fig. 18 1 Torque to 35 in-lb (4 N.m) 2 Torque to 60 ft-lb (81 N.
Parts For Monark Options A01, M01, and Q01 126 127 130 125 128 129 117 107 or 111 124 107 118 121 116 102 122 103 123 108 106 115 105 110 109 120 02434A 30 309024 119
Parts For Monark Options A01, M01, and Q01 Ref. No. Part No.
Parts Unit Frame All Options 1 Torque to 35 in–lb (4 N.m) 2 Torque to 60 ft–lb (81 N.
Parts Unit Frame All Options Ref. No. Part No. Description 2 3 5 9 12 100071 100155 100509 101747 103836 14 15 16 105751 105752 100060 LOCKNUT, hex, 3/4–16 NUT, 5/8–18 PLUG, pipe, 1/4 npt PLUG, bottom, 1/4 npt(m) SCREW, slotted head, 10–32 x 3/4 in.
Parts Unit Frame All Options 47 22 45 8 7 13 37 6 60 48 24 19 29 4 38 39 61 42 Ref.
Parts Unit Frame All Options Ref. No. Part No. Description 1 4 108036 100377 6 7 8 100737 100840 100960 11 12 108037 103836 13 104267 19 155470 21 157785 22 23 24 29 37 100081 158244 158491 177096 177117 STUD, fastener 12 SCREW, slotted head, 1/4–20 x 5/8 in. (16 mm) 2 PLUG, pipe, 1/2 npt 4 ELBOW, street, 1/4 npt (m x f) 1 GAUGE, air pressure, 0–200 psi (0–14 bar) 1 NUT, sheet spring, 10–24 12 SCREW, slotted head, 10–32 x 3/4 in.
Parts All President Options 130 129 131 134 132 133 111 or 127 117 102 124 118 127 128 121 135 102 116 126 104 107 125 103 115 106 123 122 120 Displacement Pump Combinations for Other Proportion Ratios See page 38 for adjustment ratio. Pump Combinations Proportion Ratio Volume Output gpm (l/min.) (l/min ) At 100 psi (0.7 MPa, 7 bar) psi (MPa, (MPa bar) Primary Secondary 222012 222015 1.2:1 to 5.6:1 1.10 to 0.70 (4.2 to 2.6) 1300 to 2200 (9 to 15, 90 to 152) 222012 222017 1.
Parts All President Options Ref No. 102 Part No. Description Qty Options 100103 PIN, cotter 3 A04 Ref No. 122 Description Qty Options 215925 HOUSING, VRHC 1 All PRIM. DISPL. PUMP1 PRIM. DISPL. PUMP2 PRIM. DISPL. PUMP3 PRIM. DISPL. PUMP3 PRIM. DISPL. PUMP3 PRIM. DISPL. PUMP3 PRIM. DISPL. PUMP3 SEC. DISPL. PUMP1 SEC. DISPL. PUMP2 SEC. DISPL. PUMP3 SEC. DISPL. PUMP3 SEC. DISPL. PUMP3 SEC. DISPL. PUMP3 SEC. DISPL.
Dimensions D A F G B C D H E E A 02366A B C 38 309024 Four sockets for casters. See Accessories E F G H Height President . . . . . . . . . . . . . . . . . . . 48.5” (1232 mm) Viscount . . . . . . . . . . . . . . . . . . . . 48.5” (1232 mm) Monark . . . . . . . . . . . . . . . . . . . . . 45.6” (1156 mm) Bulldog . . . . . . . . . . . . . . . . . . . . . 55.5” (1410 mm) Length . . . . . . . . . . . . . . . . . . . . . . . . . 35” (889 mm) Width . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data Motor Weight Stroke Length Effective Area President 19 lb (8.6 kg) 4 in (102 mm) 14.19 Sq in 91.55 cm Monark 13 lb (5.9 kg) 3 in (6 mm) 7.0 Sq in 45 cm2 Bulldog 78 lb (35.1 kg) 4.75 in (121 mm) 7.07 Sq in 45.61 cm Viscount I 18.5 lb (83 kg) 4 in (102 mm) 7.07 Sq in 45.61 cm Wetted Parts – See Configurator Product Order Form 309025 Pump Model Maximum Fluid Working Pressure Maximum Pump Air Input Pressure President 250 bar, 25.0 MPa (3600 psi) 12.5 bar, 1.
Graco Standard Warranty Graco warrants all equipment 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.
