Graco SuperCat 232721 Instructions-Parts List Manual Download Page 75

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308925

Troubleshooting

KEYPAD KEY AND LIGHT CONTINUITY CHECKS

Continuity Check

Green Light

Red Light

Key

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

Pin 8 and 18

Material Usage Key Light

Pin 9 and 17

Pin 10 and 17

Mix Ratio Key Light

Pin 11 and 17

Pin 12 and 17

Temperature Key Light

Pin 13 and 17

Pin 14 and 17

Work Life Timer Key Light

Pin 15 and 17

Pin 16 and 17

Up Arrow Key

Pin 23 and 25

Down Arrow Key

Pin 23 and 24

Mode Key

Pin 19 and 20

Stop Key

Pin 19 and 22

Solvent Usage Key

Pin 19 and 24

Pressure Key

Pin 19 and 25

Material Usage Key

Pin 20 and 21

Mix Ratio Key

Pin 21 and 22

Temperature Key

Pin 21 and 24

Work Life Timer Key

Pin 21 and 25

+ - + +

- + - + -

8420A

Fig. 93

Keypad Keys and Lights
Ribbon Cable (C)

Pin 1

Schematic Pump Keys Ribbon Cable (A)

Pin 1 of this connector is the second pin from
this end.

Schematic Lights Ribbon Cable (B)

Pin 1

Circuit Board

Back View of Control Access Door

Summary of Contents for SuperCat 232721

Page 1: ...rking Fluid Pressure 100 psi 0 7 MPa 7 bar Maximum Working Air Pressure 308925 rev D Read warnings and instructions See page 2 for table of contents 8787A 110474 Certified to CAN CSA 22 2 No E79 11 95...

Page 2: ...el Sensor 28 Reservoir Full Level Sensor Optional 28 Cycle Counting and Material Usage 29 Solvent Usage 29 Solvent Usage Reset 29 Pressure Sensors 30 Low Pressure A or B Optional 30 High Pressure A or...

Page 3: ...t Wet Cup 78 Bearing Lubrication 79 Air Lubrication 79 Service 80 Instruction Manuals 80 Hardware or Software Updates 80 Use of Tape 80 Required Tools 80 Removing Displacement Pumps A and B 81 Reinsta...

Page 4: ...pressure gauges and regulators and Sil ver Plus spray gun Basic assemblies do not include fluid reservoirs gravity feed fittings and hoses solvent pump fluid hoses gun swivel or spray gun Heated Mode...

Page 5: ...cement Pump Dura Flo 1200 Dura Flo 900 Dura Flo 600 308360 308354 308350 237514 236470 236458 President Air Motor 306982 207352 46 1 President Pump 307619 240445 Description Manual No Component Part N...

Page 6: ...rag Do not blow back fluid this is not an air spray system Check the gun diffuser operation weekly Refer to the gun manual Always have the tip guard and trigger guard on the spray gun when spraying Ch...

Page 7: ...uish all the open flames or pilot lights within the spray area Keep the spray area free of debris including solvent rags and gasoline Electrically disconnect all the equipment within the spray area Do...

Page 8: ...re rating of 120 F 49 C Never operate the pump without the automatic pressure relief valves installed These valves relieve fluid pressure through a drain port at the bottom of the valve if the displac...

Page 9: ...ident Solvent Pump out of view behind cabinet 121 Main Air Shutoff Valve 125e System Schematic Panel 125g Keypad with Display 202 Fluid Filter 203 Automatic Pressure Relief Valve 204 Fluid Drain Valve...

Page 10: ...g non operational periods Make sure the basic units do not have features operable that relate to the sensors on the reser voirs Check the feature and its setup to ensure its action is not related to r...

Page 11: ...P Heater 240 V single phase 16 7 A Model 245864 Viscon HP Heater 480 V single phase 8 30 A Model 245862 Viscon HP Heater Asia 200 V single phase 20 0 A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD...

Page 12: ...ervoirs set the heaters to the desired temperature open the recirculation valves and circulate the fluid using the proportioner pump When the fluid temperature in the reservoirs reaches the desired le...

Page 13: ...our Graco distributor for further informa tion Optional Heater Configurations In addition to the standard configuration described on page 12 the heaters can be installed in three optional positions in...

Page 14: ...and the heaters to protect against overpressurization should the heaters become plugged Fill the reservoirs manually Set the heaters to the desired temperature and begin spraying With this option con...

Page 15: ...fluid using the circulation pumps When the fluid temperature in the reservoirs reaches the desired level begin spraying Add material as required Fluid will continue to circulate With this option conti...

Page 16: ...ontrol to monitor both the full and low fluid levels 5 Optional Install the 240690 Level Sen sor Kit The optional 240690 Level Sensor Kit includes two level sensors to add to the two supplied with the...

Page 17: ...between the pump and the mix manifold contact your distributor for the recommended hose diameter for the best ratio assurance Do not exceed a maximum of 300 feet 91 5 m of total hose length 8 Optional...

Page 18: ...combined hose length to ensure grounding continuity Fluid hoses use only electrically conductive fluid hoses Air compressor follow manufacturer s recom mendations Spray gun ground through connection...

Page 19: ...e to fill the wet cup on page 78 Verify compatibility of the TSL with the fluids being used in the pumps During operation very small amounts of the TSL are dragged past the seals and into the pump K F...

Page 20: ...causes one of the pumps to cavitate and direct all fluid pressure to the other pump The automatic pressure relief valves automatically relieve fluid pressure if the pump output pressure exceeds 6500 p...

Page 21: ...afety 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 6 Lock the spray gun trigger safety Open Close 204 7 Open the fluid drain...

Page 22: ...part of the system Flush the entire system when the system is shut down for a long period of time Fluid Heaters WARNING COMPONENT RUPTURE HAZARD Heat causes fluid to expand If the heated fluid is trap...

Page 23: ...308925 23 Notes...

Page 24: ...tup Operator Keypad and Display Features See Fig 15 Eight function keys Up and down arrow keys Eight light indicators Six digit display Function Keys The eight function keys are used to operate and se...

Page 25: ...The solvent pump will run until the amount of solvent entered in Setup Mode is supplied In Manual Mode the feed pumps run until the fluid reaches the full level sensor or the feed pump time limit has...

Page 26: ...rm in Spray Mode 9 Constant Green Premier pump on Red Runaway pump alarm 10 Blinking Green Volume of Material A usage displayed 11 Blinking Green Volume of Material B usage displayed 10 11 Both Blinki...

Page 27: ...m schematic See the Key below for the meaning of the various ways the lights can appear and the symbols used in this manual for the light status KEY Light off function is inactive Light green function...

Page 28: ...end of the feed pump run time entered in setup NOTE The purpose of the feed pump alarm time is to help prevent the feed pump from running continuously and over filling the reservoir if the full level...

Page 29: ...ponses which include To run the solvent pump for a set number of cycles when solvent pump key is pressed To turn on the feed pumps after a set number of Premier cycles Work life time alarm Runaway pum...

Page 30: ...isplay of the pressure differential readings is indicated on the sche matic by both the High Pressure A and High Pressure B lights blinking at the same time as represented in Fig 29 3 Fig 27 A A B AB...

Page 31: ...rough the proportioner pump A pump B and total A B material usage displays the schematic light that is blinking will also switch between pump A and B in correspondence to the displayed value For total...

Page 32: ...essed to display the A or B current temperature the key 6 light turns green and the sche matic light blinks Press the keypad arrow keys to toggle between A and B while the numeric display shows the cu...

Page 33: ...will turn red and an alarm will sound NOTE The work life timer starts counting when the Premier pump stops cycling The timer resets to zero after the Premier cycles again Since the system does not mea...

Page 34: ...What the system schematic displays for that function How to change values within that function The keypad keys that are used in a procedure are indicated by numbers on the keys See Fig 36 The keypad d...

Page 35: ...ly active function key For example If you are in setup level 2 and press key 4 then press key 7 to change to setup level 3 you will enter level 3 with key 4 being the active function Arrow keys are us...

Page 36: ...rted up Access In setup level 1 press key 2 on the keypad to access the Solvent Pump Cycle Total Keypad Display The key 2 light is green and 1 appears in the keypad setup level position See Fig 39 The...

Page 37: ...usage of solvent The value is displayed when the solvent key 2 is pressed in Manual or Spray Modes Access In setup level 2 press key 2 on the keypad to access the Solvent Usage function Keypad Displa...

Page 38: ...level is reached Monitor the reservoir fill cycle to avoid overflow Access In setup level 3 press key 2 on the keypad to access the Solvent Pump Cycle Count function Keypad Display The key 2 light is...

Page 39: ...tempera ture sensors on feed pumps on and high level sen sors selected Recipes 5 6 7 and 8 cannot be changed or deleted Recipes should be recorded on copies of the form on page 58 Keep your records w...

Page 40: ...ed pumps on and high level sen sors selected Recipes 5 6 7 and 8 cannot be changed or deleted Copy the form on page 58 and use it to record your recipe settings Keep your records where they are access...

Page 41: ...in the keypad setup level position See Fig 48 System Schematic Panel The high pressure A or B light blinks See Fig 49 Changing Values Press the arrow keys to change the high pressure A or B setting Th...

Page 42: ...pad to access the Maximum Pressure Differential function Keypad Display The key 3 light is green and 2 appears in the keypad setup level position See Fig 50 System Schematic Panel The pump A and B lig...

Page 43: ...ight is green and 4 appears in the keypad setup level position See Fig 52 System Schematic Panel The light for which peak pressure is being displayed will blink See Fig 53 57 Toggling Through Pressure...

Page 44: ...B function Keypad Display The key 3 light is green and 5 appears in the keypad setup level position See Fig 58 System Schematic Panel The low pressure A and or B light blinks See Fig 59 Changing Value...

Page 45: ...ensor option Keypad Display The key 3 light is green and 6 appears in the keypad setup level position See Fig 60 System Schematic Panel The low pressure A or B lights will blink if option 1 low pressu...

Page 46: ...l position See Fig 62 The number displays in increments of 1000s For example 21 21 000 cycles System Schematic Panel The Premier Pump light blinks See Fig 63 Changing Values Value cannot be changed Pr...

Page 47: ...n the keypad setup level position See Fig 65 System Schematic Panel The pump B light blinks See Fig 66 Changing Values See the chart below for settings for the fixed ratio pumps Press the arrow keys t...

Page 48: ...e keypad setup level position See Fig 67 System Schematic Panel The pump A light blinks See Fig 68 Changing Values See the chart below for settings for the fixed ratio pumps Press the arrow keys to ch...

Page 49: ...o access the Feed Pump Alarm Time function Keypad Display The key 4 light is green and 4 appears in the keypad setup level position See Fig 69 System Schematic Panel The feed pump lights blink See Fig...

Page 50: ...servoir full level sensor and the set number of Premier pump cycles have elapsed Access In setup level 5 press key 4 on the keypad to access the Premier Pump Cycle Count function Keypad Display The ke...

Page 51: ...hange when close supervision is possible and minimizing the volume of material in the reservoir is desirable 1 Low level sensors only no feed pumps Sets the control to only monitor the Low Level Senso...

Page 52: ...Measurement function Keypad Display The key 5 light is green and 1 appears in the keypad setup level position See Fig 76 System Schematic Panel There is no system schematic display related to the unit...

Page 53: ...to change the material A tem perature high limit Fig 78 6 A A B AB A B S B A B A B S A B A B Material A Temperature Light Fig 79 Temperature Key 6 Level 2 Material A Temperature Low Limit Default Sett...

Page 54: ...ys to change the material B tem perature high limit Fig 82 6 A A B AB A B S B A B A B S A B A B Fig 83 Material B Temperature Light Temperature Key 6 Level 4 Material B Temperature Low Limit Default S...

Page 55: ...stops cycling The timer resets the set work life time after the Premier cycles again Since the system does not measure volume there are instances where the material work life time could expire without...

Page 56: ...e Sensor option Keypad Display The key 6 light is green and 6 appears in the keypad setup level position See Fig 88 System Schematic Panel The temperature limit A or B lights will blink if option 1 te...

Page 57: ...ee Fig 90 7 Press the arrow keys to toggle through the peak pressure readings and record the readings 8 As a rule start by setting the values 20 higher than the peak values recorded for High Pressure...

Page 58: ...iter High Limit B ______ F C Level 4 Peak Pressures High Pressure A _____ psi MPa bar High Pressure B _____ psi MPa bar Low Pressure A _____ psi MPa bar Low Pressure B _____ psi MPa bar Pressure Diffe...

Page 59: ...iter High Limit B ______ F C Level 4 Peak Pressures High Pressure A _____ psi MPa bar High Pressure B _____ psi MPa bar Low Pressure A _____ psi MPa bar Low Pressure B _____ psi MPa bar Pressure Diffe...

Page 60: ...nnel Fluid Path and Sensor Schematic Non Heated Systems High Pressure Sensor 7900A 3 way Valve Waste Container Waste Container Solvent Pump Mix Manifold Mixed Material Flush Complete System Flush Flui...

Page 61: ...Path and Sensor Schematic Heated Systems Mix Manifold 8721A 3 way Valve Waste Container Waste Container Solvent Pump Mixed Material Flush Complete System Flush Fluid Filter Automatic Pressure Relief V...

Page 62: ...ed replace sensor See Service on page 90 Check continuity of level sensor light See page 74 Replace circuit board See Service on page 87 Check feed pumps See page 63 Alarm does not sound Fluid below s...

Page 63: ...pumps See trouble shooting in the feed pump manual Install larger feed pumps Low level sensor alarm In spray mode Check feed pump setup See below Check feed pumps See trouble shooting in the feed pum...

Page 64: ...Premier pump See manual 308350 308354 or 308360 Replace circuit board See Service on page 87 High pressure display value does not change Check high pressure sensors See below Replace circuit board See...

Page 65: ...up on page 57 to determine the pressure alarm levels Inspect and clean sensor port Check low pressure sensors See below Replace circuit board See Service on page 87 Low pressure display value does not...

Page 66: ...e sensor that operates See Service on page 90 If sensor has failed replace sensor See Service on page 90 Check continuity of temperature sen sor light See page 74 Replace circuit board See Service on...

Page 67: ...8875 for current operation Plugged high pressure fluid filters Clean filters See Service page 77 Pump cycles when gun is not triggered In spray mode Check valve positions against posi tions shown in O...

Page 68: ...equired to provide the necessary air volume Feed pump pressure is too high Reduce feed pump pressure Feed pump pressures must be less than 25 of proportioner output pressure The displacement cylin der...

Page 69: ...lowest position when the pump stops 5 With the main air valve closed remove the screws 469 and guard 424 from the side of the propor tioner 6 Unscrew the connecting rod nut 361 from the secondary pum...

Page 70: ...308925 70 Troubleshooting Pump Lowers C D E F 8794A 8753A Fig 91 469 446 361 381 311 312 361 381 204 C 207 207 PK A B 424...

Page 71: ...ressure of proportioning pump A or B is low on the upstroke Check if the piston valve is stuck open or if the piston packings are worn Clear the piston valve replace the packings See your separate pum...

Page 72: ...ff Check solvent pump air solenoid See below Check keypad continuity See page 75 Solvent usage display value does not change In manual or spray mode Check material usage display See page 73 Air Soleno...

Page 73: ...al or spray mode Visually check wire connections Check the resistance across the sensor while moving a strong mag net in front of the sensor The reading should be less than 0 1 ohms when a magnet is i...

Page 74: ...g 93 for the associated pin numbers and locations NOTE When closed the keys should have less than 100 ohms resistance Check the lights for continuity with the leads touch ing the pins one way then rev...

Page 75: ...Pin 13 and 17 Pin 14 and 17 Work Life Timer Key Light Pin 15 and 17 Pin 16 and 17 Up Arrow Key Pin 23 and 25 Down Arrow Key Pin 23 and 24 Mode Key Pin 19 and 20 Stop Key Pin 19 and 22 Solvent Usage K...

Page 76: ...e reservoir outlet filters 54 weekly If you have the optional low pressure sensor a red light on the low pressure indicator at reservoir A or B will indicate when the filter is clogged See Fig 94 To r...

Page 77: ...le solvent 4 Reassemble the filter Refer to manual 307273 Fig 95 8339A part C 202 Agitator Care 1 Shut off the agitator air control valve D Discon nect the air line from the agitator 2 Every 8 hours a...

Page 78: ...frequently if found to be dry See Fig 98 1 Follow the Pressure Relief Procedure on page 21 2 Turn off the main air valve 3 Remove the screws 469 and the two guards 424 446 from the sides of the propor...

Page 79: ...not remove the sensor but carefully set the cover to the side without straining or damaging the sensor or cable 5 The four main bearings 497 are now exposed Grease the center of all four bearings One...

Page 80: ...l the parts Use Part No 070540 blue for component A 070541 green for component B 070542 red for mixed material and 070543 white for solvent CAUTION Wear the grounding strap provided when servicing the...

Page 81: ...displacement pumps Be sure to look at the model number and use the appropriate manual for service and reference Reinstalling Displacement Pumps A and B 1 Make sure the coupling nut 361 and the couplin...

Page 82: ...308925 82 Service 8753A Fig 100 A B 497 446 385 361 381 442 363 311 312 363 442 361 381 385 424 469 458...

Page 83: ...he air motor 310 from the frame 9 Refer to the separate manual supplied for air motor service Be sure to look at the model num ber stamped on the air motor and use the appropriate manual for service a...

Page 84: ...See Fig 102 7 You should now be able to slide the bearings 497 off of the shaft ends 8 Replace the bearings only with identical Graco replacement parts Pack the bearings in Industrial Grade 1 Heavy Du...

Page 85: ...ment rod R from the air motor adapter A Inspect the o ring B See Fig 103 6 Refer to manual 307619 to service the displace ment pump 7 Reinstall in the reverse order To service the air motor M 8 Discon...

Page 86: ...weekly Refer to page 78 3 Follow the Pressure Relief Procedure on page 21 4 Refer to the CAUTION on page 80 Label the component A and B hoses and remove them from the manifold inlet fittings 5 Loosen...

Page 87: ...the alternator Make sure the air pressure to the power supply is not set above 100 psi 0 7 MPa 7 bar Service the power supply as instructed on page 94 if necessary Replacing the Circuit Board Keypad...

Page 88: ...Remove the circuit board cover 125b 15 Disconnect the cable from the circuit board 125c Create tags or notes as required for proper instal lation of the new cable 16 Cut the wire ties holding the cabl...

Page 89: ...enoid valves available as an option Order Feed Pump Control Kit 240689 and refer to the instructions on page 8 of this manual 1 Follow the Pressure Relief Procedure on page 21 2 Turn off the air to th...

Page 90: ...stall the new sensor assembly Tighten the sensor until it bottoms out then tighten the jam nut 4 Connect the sensor assembly to the correctly labeled mating connector CA Fig 108 47 46 CA 8349A Tempera...

Page 91: ...only be torqued to 20 25 ft lb 27 34 N m A small amount of grease can be used with o ring insertion 2 Turn on the controller 3 Open the drain valves 204 on the high pressure fluid filters to ensure th...

Page 92: ...ly connector from its mating connector 4 Place a container or rag under the filter 54 to catch any remaining material Unscrew the low pressure sensor PS from the filter A small amount of fluid may dra...

Page 93: ...22 Proportioning Pump Cycle Counter 1 Follow the Pressure Relief Procedure on page 21 2 Disconnect the cycle counter sensor 465 from its mating connector Unscrew the four screws 458 and remove the bac...

Page 94: ...he resistance between the two outer terminals of the 3 wire connector c The resist ance should be 3 to 5 ohms If the reading varies from this value replace the alternator 11 Measure the resistance bet...

Page 95: ...5 Parts Heated Package Assemblies 232713 to 232724 8681A 1 Part of the standard proportioner See page 97 515 510 514 511 509 511 515 514 511 509 511 502 518 519 501 517 508 520 521 520 520 506 506 1 1...

Page 96: ...2 HEATER fluid 200V Models 232715 232719 and 232723 see manual 309524 2 508 241171 HOSE fluid supply insulated 3 8 npt m x 3 8 npsm f 50 ft 15 2 m long 1 509 114757 TEE 1 2 npt m 2 510 166866 ELBOW st...

Page 97: ...41 42 43 40 18 34 49 50 31 32 33 28 29 30 308925 97 Parts SuperCat Proportioner Fixed Ratio Part No 232096 243467 and 243617 12 x 12 2 1 Part No 232097 243468 and 243618 9 x 6 3 1 Part No 232098 24346...

Page 98: ...308925 98 Parts 8789A 8337A 53a 53b 53c 54a 54b 54c 54d 54e 56 54f 70 50 14 15 10 12 13 64 1 69 31...

Page 99: ...2 23 114557 PADLOCK guard 2 25 193277 COVER control box see page 103 1 26 114185 SCREW cap button head not shown 14 27 105468 SCREW cap hex head not shown 4 28 112117 SCREW cap hex head 5 29 108050 WA...

Page 100: ...inet not shown 1 61 552225 HOSE coupled 1 4 18 npt m solvent pump to cabi net not shown 1 Ref No Part No Description Qty 62 112190 STRAP wrist grounding not shown 1 64 240634 HOSE coupled with sani ta...

Page 101: ...308925 101 Parts 8344A part 35 Ref 17 16 Detail of Mix Manifold 117 8414A 71 48 22 23 Premier Pump Assembly 8 Parts list on page 102 20 21 465 see list on page 110...

Page 102: ...nly 1 236466 PUMP displacement see manual 308353 for parts 3 1 ratio units only 1 Ref No Part No Description Qty 312 237514 PUMP displacement see manual 308360 for parts 2 1 ratio units only 1 237510...

Page 103: ...3 104 105 106 107 109 110 110 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 130 131 132 133 134 135 136 137 138 139 142 140 141 143 144 145 146 146 147 148 158 159 160 16...

Page 104: ...npt x 1 8 npt 1 118l 108190 GAUGE air pressure 0 100 psi 0 0 7 MPa 0 7 bar range 1 118m 115243 REGULATOR air 1 4 npt 1 118n 192554 HOUSING top 1 118p 192555 HOUSING bottom 1 118q 114319 PLUG expansion...

Page 105: ...ption Qty 158 193181 HANGER mix manifold 1 159 112117 SCREW cap hex head 6 161 114183 NUT flange hex M6 6 162 114598 BRACKET filter mounting 1 164 158585 NIPPLE 1 167 114939 NIPPLE 1 168 106465 ELBOW...

Page 106: ...584 BRACKET solvent pump 1 609 114992 FITTING flare tube not shown 1 610 241247 KIT suction tube not shown 1 611 158491 NIPPLE not shown 2 612 110225 VALVE ball not shown 1 613 240185 FRAME solvent pu...

Page 107: ...ol Assembly 8339A 201 202 203 204 205 206 206 207 208 209 210 211 212 212 213 214 215 216 216 217 218 219 220 221 222 223 254 224 225 226 228 229 230 231 232 233 234 234 235 236 237 238 239 240 241 24...

Page 108: ...tem 223a see manual 306861 4 224 193168 MANIFOLD block 2 225 193183 BRACKET 2 Ref No Part No Description Qty 226 222200 VALVE fluid flow control see manual 307892 2 228 551390 BEAKER 2 229 193179 COLL...

Page 109: ...301 Frame Assembly 8409A 8410A 449 436 407 414 Ref 416 464 415 418 429 435 430 419 420 463 438 437 439 437 402 469 496 446 407 406 413 425 447 414 409 462 433 458 459 424 442 404 413 Ref 409 497 498...

Page 110: ...sleeve 2 430 626132 WASHER thrust pivots 4 433 626436 CAP lever 2 435 626446 SHAFT pivot 1 436 114384 SCREW 4 437 626460 FRAME upright 2 Ref No Part No Description Qty 438 626438 PLATE top 1 439 62643...

Page 111: ...308925 111 Notes...

Page 112: ...308925 112 Dimensions 8787A 42 in 1067 mm 66 in 1676 mm 74 in 1880 mm...

Page 113: ...steel tungsten carbide Reservoirs 304 316 Stainless steel Fluid filters 303 304 313 and 316 stainless steel polyethylene Mix manifold 17 4 PH 304 316 Stainless steel tungsten carbide Delrin PEEK Stat...

Page 114: ...rranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or an...

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