Graco 965481 User manual

INSTRUCTIONS 684-026

Revision C

Instructions

This manual contains important

warnings and information.

READ AND RETAIN FOR REFERENCE

Air-Powered Premier

Hydra-Cat®H.P.

Variable Ratio

Proportioning Pump

100 PSI (6.8 bar) Maximum Working Air Pressure

5000 PSI (333 bar) Maximum Working Fluid Pressure

Model: See Chart

WARNING

MOVING PARTS HAZARD

Relieve fluid and air pressure to unit before

servicing unit. Do not operate with panels

removed. Follow pressure relief procedure on

page 11.

WARNING

Graco Inc. does not manufacture or supply any of the reactive chemical components that are used in this equipment

and is not responsible for their effects. Because of the vast number of chemicals that could be used and their

varying chemical reactions, the buyer and user of this equipment should determine all factors relating to the fluids

used, including any of the potential hazards involved. Particular inquiry and investigation should be made into

potential dangers relating to toxic fumes, fires, explosions, reaction times, and exposure of human beings to the

individual components or their resultant mixtures. Graco assumes no responsibility for loss, damage, expense or

claims for bodily injury or property damage, direct or consequential, arising from the use of such chemical

components.

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441



Assembly Ratio Ratio

Part # Min. Max.

965-481 1.50 4.50

965-479 2.00 6.00

965-530 1.00 3.00

965-579 1.33 4.00

965-480 1.00 3.00

2 684-026

Table of Contents

Symbols............................................................................ 3

Definition of Terms........................................................... 3

Warnings.......................................................................... 3

Specification of Hydra-Cat H.P. Pumps ...........................6

Installation ........................................................................ 6

Connect the Fluid Supply Line................................... 6

Connect the Fluid Output Lines ................................. 6

System Accessories................................................... 7

Connect the Air Supply Line....................................... 7

Pressure Relief Valve ................................................ 7

Electrical Grounding................................................... 8

Ratio Adjustment.............................................................. 9

Terms......................................................................... 9

Determine the Ratio................................................. 10

Relationship Between the Primary and

Secondary Pumps ................................................ 10

Adjusting the Ratio Setting....................................... 10

Operation......................................................................11

Pressure Relief Procedure.....................................11

System Flushing.....................................................11

Start the Pump.......................................................11

Standard Operating Flushing.................................11

Checking the Ratio.................................................12

Maintenance.................................................................12

Wet Cups...............................................................12

Bearings.................................................................12

Air Lubrication........................................................13

Troubleshooting............................................................14

Troubleshooting Techniques..................................14

Troubleshooting Chart ...........................................15

Service..........................................................................16

Required Tools.......................................................16

Disconnecting the Displacement Pump.................16

Reconnecting the Displacement Pump..................17

Disconnecting the Air Motor...................................17

Reconnecting the Air Motor....................................17

Replacing the Bearings..........................................18

Dimensions...................................................................19

Air Consumption...........................................................19

Technical Data..............................................................21

Graco Phone Numbers.................................................22

The Graco Warranty and Disclaimers..........................22

684-026 3

Symbols

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.

Definition of Terms

WARNING: Alerts the user to avoid or correct conditions

which could cause serious injury.

CAUTION: Alerts the user to avoid or correct conditions

which could damage or destroy equipment.

NOTE: Identifies helpful information.

VRHC: The abbreviation for Variable Ratio Hydra–Cat

Pump. This pump automatically proportions and mixes two

fluids in a prescribed ratio, which is variable within the

ranges listed on the cover.

BASE: Also called polyol or resin, is one of two reactive

chemicals used in a plural component system.

CATALYST: Also called hardener, is the fluid which reacts

with the base fluid.

PART: An undefined unit of measurement. When you

determine the size of the unit (ounce, pint, gallon), use that

measurement consistently in setting up your system.

SPRAY GUN: This term refers to any type of spray gun or

dispensing valve used to spray or dispense the fluid being

pumped.

WARNING

PLURAL COMPONENT FLUID HAZARD

Before using this equipment, read the fluid manufacturer’s warnings and determine all facts relating to the

fluids used, including any of the potential hazards relating to toxic fumes, fires, explosions, reaction times,

and exposure of human beings to the individual components of their resultant mixtures.

x

Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state

and national guidelines.

x

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

x

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.

MOVING PARTS HAZARD

Moving parts, such as the air motor piston and the secondary pump lever and connecting rod area, can

pinch or amputate fingers.

x

Do not operate the equipment with the guards removed.

x

Keep your body and tools clear of any moving parts when starting or operating the equipment.

4 684-026

WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and result in

fire or explosion and serious injury.

x

Ground the equipment and the object being sprayed. See Electrical Grounding on page 8.

x

Extinguish all the open flames or pilot lights in the spray area.

x

Electrically disconnect all equipment in the spray area.

x

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

x

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

x

Do not smoke in the spray area.

x

Do not operate a gasoline engine in the spray area.

x

If there is any static sparking while using this equipment, stop spraying immediately. Identify and

correct the problem.

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in

serious injury.

x

This equipment is for professional use only.

x

Read all instruction manuals, tags, and labels before operating the equipment.

x

Use the equipment only for its intended purpose. If you are uncertain about the usage, call Graco

Technical Assistance at 1-800-543-0339.

x

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

x

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

x

All system components must meet or exceed the pressure ratings printed on the pressure relief valve.

The lever amplification or the secondary pump enables very high fluid pressures to be achieved. A

5000 psi working pressure range relief valve is required on both cylinders to limit the fluid pressure. Do

not tamper with the pressure relief valve or serious bodily injury could result.

x

Do not lift pressurized equipment.

x

Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not

expose Graco hoses to temperatures above 180ºF (82ºC) or below -40ºF (-40ºC).

x

Do not use hoses to pull equipment.

x

Use fluids or solvents that are compatible with the equipment wetted parts. See the Technical Data

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

x

Fluid hoses must have spring guards on both ends to protect them from rupture caused by kinks or

bends near the couplings.

x

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

684-026 5

WARNING

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.

x

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

attention.

x

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

x

Do not put your hand or fingers over the spray tip.

x

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

x

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

x

Always have the tip guard and the trigger guard on the spray gun (if so equipped) when spraying.

x

Check the spray gun diffuser (if so equipped) operation weekly. Refer to the gun manual.

x

Be sure the spray gun trigger safety operates before operating the gun.

x

Lock the spray gun trigger safety when you stop spraying.

x

Follow the Pressure Relief Procedure on page 11 when you are instructed to relieve pressure, stop

spraying, check, clean or service any system equipment, or install or change spray tips.

x

Tighten all fluid connections before each use.

x

Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Permanently coupled hoses cannot be repaired.

x

Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and hot

surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to temperatures above

180ºF (82ºC) or below -40ºF (-40ºC).

6 684-026

Specifications of Hydra–Cat H.P. Pumps

The following chart gives specifications for the Hydra-Cat

H.P. pumps, using No. 10 weight oil. The volumetric ratio

is expressed as the proportion of the volume of fluid of the

primary pump compared to the volume of fluid of the

secondary pump.

For example, Model 965-480 has a minimum volumetric

ratio of 1:1. At this setting the primary and secondary

pumps combined will deliver an output of 6.1 gpm. The

maximum volumetric ratio for Model 965-480 is 3:1 and

the combined output at that setting is 4.1 gpm.

Ratio At Minimum Ratio Settin

At Maximum Ratio Settin

Lower ID

Air Motor Assembl

Min Max Stall Stall Out

ut Out

ut Stall Stall Out

ut Out

ut Master Slave

Part No. PSI Bar GPM LPM PSI Bar GPM LPM DF DF

Premier 965-481 1.50 4.50 5333 368 3.8 14.4 7273 502 2.8 10.6 9 6

Premier 965-479 2.00 6.00 4444 307 4.6 17.3 5714 394 3.6 13.4 12 6

Premier 965-530 1.00 3.00 4444 307 4.6 17.3 6667 460 3.0 11.5 9 9

Premier 965-579 1.33 4.00 3810 263 5.3 20.2 5333 368 3.8 14.4 12 9

Premier 965-480 1.00 3.00 3333 230 6.1 23.0 5000 345 4.1 15.4 12 12

Kin

965-477 1.00 3.00 3803 262 3.0 11.5 5704 393 2.0 7.7 6 6

Kin

965-478 1.50 4.50 3042 210 3.8 14.4 4148 286 2.8 10.6 9 6

Kin

965-524 2.00 6.00 2535 175 4.6 17.3 3259 225 3.6 13.4 12 6

Kin

965-466 3.00 9.00 1901 131 6.1 23.0 2282 157 5.1 19.2 18 6

Note: All Output Pressures Limited To 5000 PSI By Integral Pressure Relief Valves

Note: Pressure outputs calculated at 100 PSI Air Pressure for Premier and 90 PSI Air Pressure for King

Note: Volume outputs calculated at 40 cycles per minute.

Installation

The Typical Installation shown is only a guide to setting up

the complete Hydra-Cat H.P. system. For assistance in

designing a system to suit your particular needs, contact

your nearest Graco representative.

NOTE: The reference numbers and letters in the text

correspond to the numbers and letters in the drawings.

Location

Sit the proportioner on a flat floor surface.

Connect the Fluid Supply Lines

Connect the grounded fluid hoses to the pump inlet fittings

(P, R). If the unit will be pressure fed from separate supply

units, install a fluid pressure gauge at each inlet.

NOTE: The pressurized fluid supplies must not exceed 1/4

of the operating fluid pressure of the pump. Pressure above

that level will feed right through the pump and improper

rationing will result.

Connect the Fluid Output Lines

Connect electronically conductive fluid hoses to the pump

outlet fittings. Tighten all of the fittings.

Fig. 1

684-026 7

KEY

A Bleeder Type

Main Air Valve

B Air Regulator

C Pressure Relief Valve

D Mix Manifold

E Air Supply Line

F Air Line Filter

G Air Shutoff Valve

H Air Line Lubricator

J Base Supply Pump

K Catalyst Supply

Pressure Pot

L Solvent Supply Pump

M Mix Manifold Flush Inlet

N Static Mixer

P Primary Pump Inlet

R Secondary Pump Inlet

S Ratio Adjustment Screw

T Spray Gun

U Ratio Indicator Plate

V Ratio Indicator Pin

Fig. 2 Typical Installation

System Accessories Connect the Air Supply Line

Refer to Fig. 2.

NOTE: To ensure the maximum pump performance and

safety, be sure that all the accessories used are properly

sized to meet your system requirements and the pressure

limits of the pump. Use only genuine Graco parts and

accessories.

In the air line, install an air filter (F) to remove harmful dirt

and moisture from the compressed air supply. Install an air

line lubricator (H) downstream from the air filter, the air

regulator (B) and the bleed-type master air valve (A). A

lubricator will provide automatic lubrication to the air motor.

Connect an electrically conductive air supply hose to the

3/4” npt(f) port of the air manifold (B). Open the bleed-type

master air valve (A) and, using the pressure gauge, set the

air regulator (B) to the desired pressure. See the Typical

Installation and the Parts Drawing.

Pressure Relief Valve

All components have rated working pressures of 5000 psi

(345 bar) or greater. For more information about the

pressure relief valve, see instruction manual 308-547.

WARNING

A bleed-type master air valve (A) is required in your

system to relieve the air trapped between the valve and

the pump after the pump is shut off. Trapped air can

cause the pump to cycle unexpectedly, resulting in

possible serious injury, including amputation.

8 684-026

Electrical Grounding

WARNING 4.

Spray gun or dispensing valve:

Obtain grounding

through connection to a properly grounded fluid hose

and pump.

FIRE AND EXPLOSION HAZARD

Static electricity is created by the high velocity

flow of fluid through the pump and hose. If your

system is not properly grounded, sparking may

occur and the system may become hazardous.

To reduce the risk of static sparking which can

result in a fire or explosion and cause serious

injury, follow these recommendations for

providing electrical continuity throughout your

system.

Also, read the WARNING section, FIRE AND

EXPLOSION HAZARD on page 4.

Fluid supply container:

according to your local code.

Object being sprayed:

according to local code.

All solvent pails

used when flushing, according to local

code.

Use only metal pails

which are conductive,

placed on a positively grounded surface. Do not place

the pail on a non-conductive surface, such as paper or

cardboard, which interrupts the grounding continuity.

To maintain grounding continuity when flushing or

relieving pressure,

always hold a metal part of the gun

or dispensing valve firmly to the side of a grounded

metal pail, then trigger the gun.

Pump:

Loosen the grounding lug locknut (A) and

washer. Insert one end of a 12 ga (1.5 m2) minimum

ground wire (B) into the slot in the lug (C). Tighten the

locknut securely. See Fig. 3. Connect the other end of

the ground wire to a true earth ground. Order a

Grounding Clamp, P/N 103-538, and a Grounding Wire,

P/N 208-950, (25 feet (7.6 m) long, 12 ga.).

Air and fluid hoses:

Use only electrically conductive

hoses with a maximum of 500 feet (150 m) combined

hose length to ensure grounding continuity.

Air compressor:

follow the air compressor

manufacturer’s recommendations

Fig. 3 0720

684-026 9

Ratio Adjustment

Understanding the terms used with the Hydra–Cat (H.P.)

System, how it functions, and how to find and set the

correct ratios for your application is the key to easier, more

versatile operation of your proportional system.

Be sure to read and understand the following information

before operating the equipment.

Terms

Ratio refers to the simultaneous output of a certain volume

of fluid by the primary and secondary pumps.

The primary pump (A) is directly under the air motor (H);

it usually pumps the base fluid. The secondary pump (B)

is on the opposite end of the lever arm (E); it usually

pumps the catalyst. The ratio of the secondary pump(s)

can be changed by adjusting the ratio adjustment screw

(C). See Fig. 4.

There are three main steps when applying the use of ratios:

(1) determine the ratio that is required, (2) calculate the

ratio setting, and (3) set the ratio on the Hydra-Cat H.P.

system.

Key

A Primary Pump

B Secondary Pump

C Ratio Adjustment Screw

D Wet Cups

E Fulcrum and Arm

F Primary Pump Output

G Secondary Pump Output

H Air Motor

I Air Input

J Bleed Type Master Air Valve

Fig. 4

10 684-026

Determine the Ratio

Set the ratio based on your situation. If :

x

The fluids are supplied at a ready–to–spray

viscosity, simply set the ratio as explained under

Adjusting the Ratio.

x

The fluids are NOT supplied at ready–to–spray

viscosity, the ratio must be determined after the

reducer is added to the base, as instructed in

Procedure 1, below.

NOTE: Evaporation of the reducer in the base causes

changes in the ratio. To prevent evaporation, store

the base in a closed container.

NOTE: Some reducers have very little ability to lubricate

and many cause seals to dry out. To prolong the

seal life, be sure your pump seals are compatible

with the base’s reducer. Contact your Graco

representative for the correct seals to use.

Procedure 1: Base is not pre-reduced

When adding the reducer to the base before proportioning

with the VRHC system, determine the ratio of the

base/reducer mixture to the catalyst in order to set the

proper ratio.

Example:

The instructions on the can say “Mix 5 parts base to 1 part

catalyst. Then reduce 3 parts of this mixture to 1 part

reducer.”

1. Add the parts of the base and catalyst to find the parts

mixture.

5parts base

+ 1parts catalyst

6parts mixture

2. The next statement on the can says, “Reduce 3 parts of

the mixture.” So divide the parts of the mixture by 3 parts

to reduce to find the parts reducer.

6parts mixture

/ 3parts to reduce

2parts reducer

3. To determine the ratio of the secondary pump, add the

appropriate parts of base and reducer to find the parts

combined base/reducer.

5parts base

+ 2parts reducer

7parts combined base/reducer to

1 part catalyst

The ratio of the pump is 7:1.

Relationship Between the Primary and

Secondary Pumps

Moving the fulcrum point away from the primary pump

reduces the secondary stroke length, reducing its fluid

output. Moving the fulcrum point closer to the primary pump

increases the secondary stroke length, increasing its fluid

output.

Fig. 5 shows the relationship between the primary pump

and the secondary pump.

Adjusting the Ratio

See Fig. 2. Use a wrench to rotate the ratio adjustment

screw (S). Rotating the screw clockwise will increase the

ratio. Rotating the screw counterclockwise will decrease

the ratio. The indicator pin (V) will move along the ratio

indicator scale (U) as the ratio adjustment screw is rotated.

When the pin is above the desired ratio, remove the

wrench and perform a ratio test as described on page 12.

Fig. 5

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