Graco Power-Flo Senator User manual

Instructions -- Parts List

Kingr, Bulldogr, and SenatorrPumps, with Priming Piston and Severe--Duty

Displacement Pump

Power--FlorPumps

15:1 Ratio Senator Pump

10.5 MPa, 105 bar (1500 psi) Maximum Working Pressure

Model 222518, Series A

200 liter (55 gallon) drum size, Standard Air Motor

25:1 Ratio Bulldog Pumps

17.5 MPa, 175 bar (2500 psi) Maximum Working Pressure

Model 222527, Series A

200 liter (55 gallon) drum size, Standard Air Motor

Model 222528, Series A

19 liter (5 gallon) ram size, Standard Air Motor

Model 223985, Series A

200 liter (55 gallon) drum size, Quiet Air Motor

Model 223986, Series A

19 liter (5 gallon) ram size, Quiet Air Motor

55:1 Ratio King Pumps

34.5 MPa, 345 bar (5000 psi) Maximum Working Pressure

Model 222545, Series B

200 liter (55 gallon) drum size, Standard Air Motor

Model 223992, Series B

200 liter (55 gallon) drum size, Quiet Air Motor

307982J

Read warnings and instructions.

See page 2 for table of contents.

TI1597A

2 307982

Table of Contents

Warnings 2......................................

Installation 7.....................................

Operation 8.....................................

Troubleshooting 12...............................

Displacement Pump Service 14....................

Parts Lists and Drawings 18.......................

Technical Data and Performance Charts 22..........

15:1 Ratio Senator Pump 22.....................

25:1 Ratio Bulldog Pump 23.....................

55:1 Ratio King Pumps 24.......................

Dimensions 25...................................

Air Motor Mounting Layout 25......................

Graco Warranty 26...............................

Graco Information 26.............................

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious

injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

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

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

DThis equipment is for professional use only.

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

DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

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

DCheck equipment daily. Repair or replace worn or damaged parts immediately.

DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data

for your equipment. Do not exceed the maximum working pressure of the lowest rated component

in your system.

DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-

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

DHandle hoses carefully. Do not pull on hoses to move equipment.

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

Graco hoses to temperatures above 66_C (150_F) or below --40_C(--40_F).

DWear hearing protection when operating this equipment.

DDo not move or lift pressurized equipment.

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

3307982

WARNING

INJECTION HAZARD

Spray from the valve, leaks or ruptured components can inject fluid into your body and cause ex-

tremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can

also cause serious injury.

DFluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious

injury. Get immediate medical attention.

DDo not point the valve at anyone or at any part of the body.

DDo not put your hand or fingers over the valve tip.

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

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

DAlways have the tip guard and the trigger guard on the valve when spraying.

DBe sure the valve trigger safety operates before dispensing.

DLock the valve trigger safety when you stop dispensing.

DFollow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

DTighten all fluid connections before operating the equipment.

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

Permanently coupled hoses cannot be repaired; replace the entire hose.

MOVING PARTS HAZARD

Moving parts, such as the pump’s priming piston, can pinch or amputate your fingers.

DKeep clear of all moving parts when starting or operating the pump.

DKeep hands and fingers away from the priming piston during operation and whenever the pump is

charged with air.

DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 8 to

prevent the equipment from starting unexpectedly.

4 307982

WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-

sult in a fire or explosion and serious injury.

DGround the equipment and the object being sprayed. Refer to Grounding on page 6.

DIf there is any static sparking or you feel an electric shock while using this equipment, stop spray-

ing immediately. Do not use the equipment until you identify and correct the problem.

DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid

being sprayed.

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

DBefore operating this equipment, electrically disconnect all equipment in the spray area.

DBefore operating this equipment, extinguish all open flames or pilot lights in the spray area.

DDo not smoke in the spray area.

DDo not turn on or off any light switch in the spray area while spraying or while operating if fumes

are present.

DDo not operate a gasoline engine in the spray area.

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.

DKnow the specific hazards of the fluid you are using.

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

state and national guidelines.

DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and

solvent manufacturer.

5307982

Notes

6 307982

Installation

General Information

NOTE: Reference numbers and letters in parentheses

in the text refer to the callouts in the Installation and

Parts drawings.

NOTE: Always use Genuine Graco Parts and Acces-

sories, available from your Graco distributor.

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. King Pumps: Use a ground wire and clamp as

shown in Fig. 1. Remove the ground screw (Z) and

insert through eye of ring terminal at the end of

ground wire (Y). Fasten ground screw back onto

pump and tighten securely. Connect the other end

of the wire to a true earth ground. Order Part No.

222011 Ground Wire and Clamp.

Bulldog Pumps: Use a ground wire and clamp as

shown in Fig. 2. Loosen the grounding lug locknut

(W) and washer (X). Insert one end of a 12 ga (1.5

) minimum ground wire (Y) into the slot in lug

(Z) and tighten the locknut securely. Connect the

other end of the wire to a true earth ground. Order

Part No. 237569 Ground Wire and Clamp.

2. Air and fluid hoses: Use only electrically conduc-

tive hoses with a maximum of 500 ft (150 m)

combined hose length to ensure grounding conti-

nuity,

3. Air compressor: Follow the manufacturer’s recom-

mendations.

4. Spray gun/dispensing valve: Grounding is obtained

through connection to a properly grounded fluid

hose and pump.

5. Fluid supply container: According to your local

code

6. Object being sprayed: According to your local

code.

7. All solvent pails used when flushing: According to

your local code. Use only metal pails, which are

conductive, placed on a grounded surface. Do not

place the pail on a nonconductive surface, such as

paper or cardboard, which interrupts the grounding

continuity.

8. To maintain grounding continuity when flushing or

relieving pressure, always hold a metal part of the

gun/valve firmly to the side of a grounded metal

pail, then trigger the gun/valve.

Fig. 1

TI1052

Fig. 2

7307982

Installation

Air Line Filter

Air Line Lubricator

Bleed--Type Master Air Valve

Air Regulator and Gauge

Fluid Drain Valve

Grounded Fluid Supply Hose

Whip Hose

Air Supply Hose to Pump

3/4 npsm(f) Air Inlet

Pump Runaway Valve

Air Supply Hose to Elevator

Pump Ground Wire

KEY

Typical Installation

NR F

The Typical Installation above is only a guide to

selecting and installing accessories. For assistance in

designing a system to meet your needs, contact your

Graco distributor.

The Dimensional Drawings on page 25 provide

necessary measurements for installing the pump on a

custom designed mounting.

System Accessories

Refer to the Typical Installation drawing, above for

assistance in setting up your system. If you supply

your own accessories, be sure they are adequately

sized to meet the system’s requirements. If your pump

is mounted in a ram or elevator, refer to the manual

supplied with it for installation and operation instruc-

tions.

Install the accessories in the order shown in the Typi-

cal Installation drawing. The pump runaway valve (R)

senses when the pump is running too fast and shuts

off the air supply to the motor. The air line lubricator

(F) provides automatic air motor lubrication. The

bleed--type master air valve (G) relieves air trapped

between it and the pump when it is closed. Be sure the

valve is easily accessible from the pump. The air

regulator (H) controls pump speed and outlet pressure.

The air line filter (E) removes harmful dirt and moisture

from the compressed air supply.

WARNING

A bleed-type master air valve (G) and a fluid drain

valve (J) are required in your system. These acces-

sories help reduce the risk of serious injury includ-

ing fluid injection, splashing in the eyes or on the

skin, and injury from moving parts if you are adjust-

ing or repairing the pump.

The bleed-type master air valve relieves air trapped

between this valve and the pump after the air is

shut off. Trapped air can cause the pump to cycle

unexpectedly . Position the valve close to the

pump.

The fluid drain valve assists in relieving fluid pres-

sure in the displacement pump, hose, and spray

gun; triggering the spray gun to relieve pressure

may not be sufficient.

Using a suitable adapter, connect a fluid drain valve (J)

near the 1 in. npt(f) fluid outlet of the pump. Then

connect a grounded fluid supply hose (K). For more

flexible spray gun movement, use a shorter 13 mm

(1/2 in.) ID hose (L) between the spray gun and the

main hose.

8 307982

Operation

Pressure Relief Procedure

WARNING

INJECTION HAZARD

Fluid under high pressure can be in-

jected through the skin and cause seri-

ous injury. To reduce the risk of an injury

from injection, splashing fluid, or moving parts, fol-

low the Pressure Relief Procedure whenever you:

Dare instructed to relieve the pressure,

Dstop spraying/dispensing,

Dcheck or service any of the system equipment,

Dor install or clean the spray tips/nozzles.

1. Lock the gun/valve trigger safety.

2. Shut off the air to the pump.

3. Close the bleed-type master air valve (required in

your system).

4. Unlock the gun/valve trigger safety.

5. Hold a metal part of the gun/valve firmly to the side

of a grounded metal pail, and trigger the gun/valve

to relieve pressure.

6. Lock the gun/valve trigger safety.

7. Open the drain valve and/or the pump bleeder

valve (required in your system), having a container

ready to catch the drainage.

8. Leave the drain valve open until you are ready to

dispense again.

If you suspect that the spray tip or hose is completely

clogged, or that pressure has not been fully relieved

after following the steps above, very slowly loosen the

tip guard retaining nut or hose end coupling and relieve

pressure gradually, then loosen completely, then clear

the tip or hose.

WARNING

MOVING PARTS HAZARD

Moving parts can pinch or amputate your

fingers or other body parts. When the

pump is operating, the priming piston (Q)

(located at the pump intake) and the air motor pis-

ton (located behind the air motor shield) move.

Therefore, never operate the pump with the air mo-

tor shield removed, and keep your fingers and

hands away from the priming piston.

Before attempting to clear an obstruction from the

priming piston (Q) or service the pump, follow the

Pressure Relief Procedure at left to prevent the

pump from starting accidentally.

Flush the Pump Before Using

The pump is tested with lightweight oil, which is left in

to protect the pump parts. If the fluid you are using

may be contaminated by the oil, flush it out with a

compatible solvent before using the pump.

Keep the wet-cup (136) one-half full with Graco Throat

Seal Liquid (TSL), to help prevent the fluid being

pumped from drying on the displacement rod and

damaging the packings. Do not use TSL with food or

sanitary applications.

WARNING

For your safety, read the warning section Fire or

Explosion Hazard on page 4 before flushing, and

follow all recommendations given there.

9307982

Operation

Starting and Adjusting the Pump

1. Make sure the air regulator (H) is closed.

2. Open the bleed--type master air valve (G).

3. Hold a metal part of the spray gun firmly to the

side of a grounded metal pail and hold the trigger

open. Now slowly open the air regulator until the

pump starts. See the Typical Installation on page

4. Cycle the pump slowly until all the air is pushed

out and the pump and hoses are fully primed.

5. Release the spray gun trigger and engage the

safety latch. The pump will stall against pressure

when the trigger is released.

6. If the pump fails to prime properly, open the bleed-

er valve plug (139) slightly. Use the bleeder hole

(P) on the underside of the valve body (138) as a

priming valve until the fluid appears at the hole.

See Fig. 3.

7. Close the bleeder valve plug (139).

WARNING

To reduce the risk of fluid injection, do not use your

hand or fingers to cover the bleeder hole when

priming the pump.

With the pump and lines primed, and with adequate air

pressure and volume supplied, the pump will start and

stop as the spray gun is opened and closed.

Use the air regulator to control the pump speed and

the fluid pressure. Always use the lowest air pressure

necessary to get the desired results. Higher pressures

cause premature tip/nozzle and pump wear.

WARNING

To reduce the risk of overpressurizing your system,

which could result in component rupture and cause

serious bodily injury, never exceed 0.7 MPa, 7 bar

(100 psi) incoming air pressure to the pump.

Fig. 3

136

139

138

Never allow the pump to run dry of the fluid being

pumped. A dry pump will quickly accelerate to a high

speed, possibly damaging itself. A pump runaway

valve, which shuts off the air supply to the pump if the

pump accelerates beyond the pre--set speed, is avail-

able.

If your pump accelerates quickly, or is running too fast,

stop it immediately and check the fluid supply. If the

supply container is empty and air has been pumped

into the lines, refill the container and prime the pump

and the lines with fluid, or flush and leave it filled with a

compatible solvent. Be sure to eliminate all air from

fluid system.

10 307982

Operation

Shutdown and Care of the Pump

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

For overnight shutdown, follow the Pressure Relief

Procedure on page 8. Always stop the pump at the

bottom of the stroke to prevent the fluid from drying on

the exposed displacement rod and damaging the

throat packings.

Every 40 hours of operation, check that the packing

nut/wet cup is tight. Follow the Pressure Relief Pro-

cedure and tighten the nut just snug -- do not overtigh-

ten, or the packings may be damaged.

Flushing

To reduce the risk of fluid injection injury, static spark-

ing, or splashing in the eyes or on the skin, relieve the

pressure, and remove the spray tip (spray guns or

spray valves only) before flushing. Hold a metal part of

the gun/valve firmly to the side of a grounded metal

pail and use the lowest possible fluid pressure during

flushing.

Always flush the pump before the fluid dries on the

displacement rod. Never leave water or water--based

fluid in the pump overnight. First, flush with water or a

compatible solvent, then with mineral spirits. Relieve

the pressure, but leave the mineral spirits in the pump

to protect the parts from corrosion.

Lubrication

The accessory air line lubricator (F) provides automatic

air motor lubrication. For daily manual lubrication,

disconnect the air supply, place about 15 drops of light

machine oil in the pump air inlet, and reconnect the air

supply to blow oil into the motor.

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