INSTRUCTIONS-PARTS LIST.

0-

READ manual contains

AND RETAIN

IMPORTANT

FOR REFERENCE

AIRGARD"

Pump Runaway Valve

120 psi (8.4

bar) kXlMUM AIR INLET PRESSURE

w

Model 224-040, Series A

308-201

Rev A

Warnings..

Installation

Operation

Troubleshooting..

Service

...............................

...........................

Parts Drawing and List

Dimensional Drawing

...............

.....

2,3

. 4

.5

. 6

Back Cover

Back Cover

Warranty Back Cover

Graco Toll-Free Phone Numbers Back Cover

. 2

. 7

GRACO INC. P.0. BOX 1441 MINNEAPOLIS, MN 55440-1441

0 1992, GRACO INC.

OBSERVE ALL WARNINGS. Read And Understand All Instruction Manuals Before Operating Equipment.

Use Only With Compressed Air

This valve is for useonfywithcompressedair. It is not designed for use with any other power source. NEVER use any other gas or fluid in the runaway valve.

General Safety

Any misuse of the runaway valve, such as overpressurizing, modifyingparts,orusingwomordamagedparts,cancausethe valveto ruptureand result inseriousinjuryorpropertydamage.

NEVER alter or modify any part of the runaway valve; doing so could cause it to malfunction.

Moving Parts Hazard

To reduce the risk of serious injury, including pinching or am- putationoffingersorhands, NEVERusetherunawayvalveasa pump shutoff vaNe. The valve does not completely shut off the airsupply,and thepumpwillcontinuetooperateslowlyafterthe valve closes. The air motor piston (located behind the air motor platesorshield) moveswhenairissuppliedtothemotor.NEVER operate the pump wlth the air motor plates or shield removed.

System Pressure

NEVER exceed 120 psi (8.4 bar) MAXIMUM AIR INLET PRES-

SURE to the vaive, or your pump. the maximum air inlet pressure stated on

DONOTexceedthemaximumworkingpressureofanycompo- nent or accessory used in the system.

CHECK all equipment regularly and repair or replace worn or damaged parts immediately.

Alwayswearprotectiveeyewear,gloves,clothingandrespirator as recommended by the fluid and solvent manufacturer.

Pressure Relief Procedure

To reduce the risk of serious injury, includin injury from moving parts, are alwaysfollowthisprocedurew 3, eneveryou servicing the runaway valve.

1. Follow the Pressure Relief Procedure in your sepa- rate pump manual.

2. Shut off the main air shutoff valve.

Alwaysfollowthe Pressure Relief Procedureinyourseparate pump manual, before checking, clearing, cleaning, flushing or servicing any part of the system.

IMPORTANT

United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards - particularly the General Standards, Pati1910, and the Construction Standards, Part 1926 - should be consulted.

INSTALLATION

Reference letters and numbers in the text refer to Figs 1 and 2 and the Parts Drawing on page 7.

Install an air filter (A) to remove harmful dirt and moisture from the compressed air supply. Install a main air shutoff valve (6) to isolate the runaway valve for servicing. If you supply your own accessories, be sure they are ade- quately sized and pressure-rated to meet the system’s requirements.

Installing the Runaway Valve on King’“, Bulldoge, and Senatore Motors

Detail Aof Fig 1 shows the runaway valve (D) used with a

Bulldoge air motor, mounted on a cart. Mounting on a wall bracket is done the same way. Install the runaway valve between the air manifold (E) and the air regulator

(F), using necessary adapters. Use the 90” swivel adapter (G, supplied) to connect the runaway valve out- let to the air regulator inlet.

The Typical Installations shown on page 3 are only ex- amples Contact your Grace representative or Grace

Technical Assistance (see back page) for assistance in designing a system to meet your particular needs. install one runaway valve for each pump; the valve will control only one pump. lnstalltng the Runaway Valve on Presidente Motors

Details B and C of Fig 1 show the runaway valve (D) used with a Presidente air motor, mounted on a wall and on a cart. Install the runaway valve between the air regu- lator (F) and the bleed-type master air valve (C), using necessary adapters. Use the 90” swivel adapter (G, supplied) to connect the runaway valve outlet to the bleed valve inlet.

WARNING

A bleed-type master air valve (C) is required in your system. The bleed-type master air valve re- lieves air trapped between this valve and the pump after the air is shut off. Trapped air can cause the pump to cycle unexpectedly. Locate the valve close to the pump.

Signal Port (See Fig 2)

When the runaway valve trips, the signal port (S) is pres- surized. This air pressure will operate a pilot-operated valve to turn on a remote device such as a signal lamp or alarm. The pressure at this port will be 15% less than the inbound air pressure. the port will be low.

The volume ofairpassing through

When no remote sensor is being used, this port is plugged with a screw (3).

2 308-201

TYPICAL INSTALLATIONS

KEY

C

E

F

Q

Air Line Filter

Main Air Shutoff Valve

Air Valve

(required, for pump)

Pump Runaway Valve

Air Manifold

Air Regulator

Runaway Valve Swivel (supplied)

RECOMMENDED ADAPTERS

175-013 Nipple: 314 npt

160427 Swivel Adapter;

314 npt(m) x x 112 npt

314 npsm(f)

DETAIL B (WALL-MOUNTED DETAIL

MAIN AIR LIN

B

C (CART-MOUNTED

PRESIDENT AIR MOTOR) c

/

Fig 1

308-201

01267

3

CAUSES OF A RUNAWAY PUMP

Pump runaway refers to a rapid acceleration in pump speed, which can result in serious damage to the pump parts caused by overheating and scoring. Conditions pump runaway are:

The fluid supply container is empty, or the fluid supply has been interrupted. its prime because an air pocket has formed around the pump intake. This happens most frequently with high- ly viscous fluids. pump has ruptured, resulting in an increased pump cycle rate.

NOTE: The runaway valve may also trip if changes to the system result example, if you increase the number of gun drops, you should readjust the valve for the increased cycle.rate.

When in a runaway condition, the pump requires much more air than during normal operation. The runaway valve senses this rapid increase in the volume of air be- ing .used and greatly reduces the air flow, slowing the pump to a crawl.

NOTE: The sudden surge of air when starting the valve to trip. Turn on the air ly, or readjust the valve.

ADJUSTING THE VALVE

1. Loosen the adjustment locknut (24). See Fig 2.

2. Check that the T-handle (2) counterclockwise. is turned all the way

3. Open the dispensing valve or trigger the spray gun.

4. Slowly open the main air shutoff valve (B), the air regulator

(C).

(F),

See Fig 1. and the bleed-type master air valve

NOTE A faint hissing sound from the runaway valve normal. The valve vents a small amount of air from the poppet vent (H)

5. Adjust the pump to the desired regulated air pres- sure and cycle rate.

6. Turn the T-handle valve trips. Press and hold will feel pressure

(2) clockwise until the runaway die (2) counterclockwise (approximately 1 to turns) until pressure on the RESET valve decreases.

Release the RESET valve.

(R); you

5

NOTE: At low pressure or a slow cycle rate, perform step 6, then turn theT-handle (2) clockwise un-

SET valve (R). (Turn it approximately half the counterclockwise distance in step 6.) This may take several tries to achieve the proper setting.

7. Tighten the locknut (24).

8. Test the runaway valve as described in the following paragraph.

TESTING THE VALVE

To test the runaway valve, press the TEST valve 0. runaway valve should trip. Start the pump by pressing the RESET valve (R) and holding it in for 5

The seconds.

RESETTING THE VALVE

1. Determine the condition that caused the runaway valve to trip. Correct the condition. off, turn it back on slowly. A sud- to trip.

3. Press the RESET valve (R) and hold it in.for 5 se- conds. The pump should restart.

NOTE: In some installations, low air volume, it may the air supply to reset the valve.

Fig 2

4 308-201

2

01263

TROUBLESHOOTING CHART

I

CAUSE

I

SOLUTION

Valve does not slow down pump when It should; pump runs away

Valve is not adjusted properly. Readjust valve and test. See page 4.

Ruptured diaphragm. (If diaphragm is rup- tured, the TEST bunon will have no speed to decrease. has caused pump

See page 6.

Readjust valve and test. page 4.

Constant blast of air from vent when air supply is turned on.

Poppet valve (11, 14, 15) is stuck closed.

Poppet valve (1 1, 14, 15) is stuck open.

Valve shuts down for no apparent reason to

Disassemble and clean valve. Replace O-rings. Piston is stuck.

See page 6.

Increased air pressure has caused pump Readjust valve and

See page 6. page 6.

Interrupted or exhausted fluid supply. Check fluid supply and ensure that remains constant.

Valve is not adjusted properly.

See page 4.

See page 4.

1

Decreased pump outlet pressure.

Alr blowing from poppet vent.

Poppet vent hole plugged.

Check for properly adjusted fluid outlet pressure.

Valvedoesnotresetwhen

RESET valve is pressed

Defective poppet valve. Check and repair. page 6.

~

,

Air leaking around too quickly.

TEST valve. Replace

Press RESET valve.

Piston is stuck; no air is escaping from vent. Disassemble and clean runaway valve. 6.

Remove RESET valve. Clean needle and seat area.

See page 6.

I

See page 4.

Disassemble and clean poppet valve. page 6.

308-201 5

SERVICE

TOOLS REQUIRED

.

.

.

.

.

.

.

.

.

.

IO mm socket wrench t 1 I1 6” socket wrench

Adjustable wrench

Torque wrench

I” crow%-foot

I//;;;3 mm) brass rod, or a press

Small needle-nose pliers

O-ring pick

Thread lubricant

DISASSEMBLY (See the Parts Drawing on page 7)

NOTE: Reoair Kit 224-937 is available to service the dia- phiagm and o-rings. For best results, use all parts in the kit. Parts included in the kit are marked with an asterisk (for example, 4*). l. Follow the Pressure Relief Procedure Warning in your separate pump manual. Shut off the main air valve. Tighten the locknut (24) to lock the valve at its current adjustment. Remove the runaway valve from the air line.

2. Place the valve in a vise with the T-handle (2) facing left and the poppet valve cap (25) facing upward.

Unscrew the adapter (34) from the valve outlet.

3. Using an adjustable wrench on the flats, unscrew the stem guide (17) from the lower housing (22).

The adjustment screw (21) will come free with the stem guide and connecting parts.

4. Reach into the valve outlet and push out the piston

(16). Remove the o-rings (6,36) from the piston.

5. Insert a brass rod into the valve outlet so it contacts the valve body (16). Tap the rod with a mallet to un- seat the valve body. (This can also be done with a press.) Push the valve body out of the housing (22).

6. Remove the o-rings (5, 7) from the valve body (16).

Remove the gasket (13) from ih& housing (22).

7. Using an 1 l/16” socket wrench, loosen but do not remove the cap (25) from the upper housing (23). a. Using a IO mm socket wrench, remove the four screws (9) .and lo&washers (I). Pull the upper housing (23) away from the lower housing (22). Re- move the diaphragm (27).

9. Unscrew the cap (25) from the upper housing (23).

Remove the gasket (IO) from the cap. Remove the poppet valve spring (1 I). Push down on the poppet so the dowel pin (6) protrudes from the hole on the inside of the housing (23).

10, Remove the poppet (14), push pin (15), and o-ring

(1) from the upper housing (23). Working on the in- side of the housing (23), grasp the dowel pin (6) with a needle-nose pliers and pull it.out of the housing.

11. Unscrew the valire housing (19) and pull the RESET valve assembly out of the upper housing (23).

NOTE: The RESET valve assembly is press-fit together.

Do not disassemble it unless the needle (20) or valve housing (19) require replacement.

6 308-201

NOTE: The TEST valve assembly is also press-fit lo- gether. Do not disassemble it unless it is leaking and the parts require replacement.

12. Clean all parts and inspect for damage. Se sure to clean all air passages, cavities, and surfaces.

REASSEMBLY (See the Parts Drawing on page 7)

1. Place the upper housing (23) in a vise. Install the RE-

SET valve In the upper housing. Tighten the valve housing (19) to secure.

2. Install the diaphragm (27’) in the lower housing (22) so the larger center plate of the diaphragm is facing outward. Align the four large holes in the diaphragm with the four threaded holes in the housing.

3. Lubricate the dowel pin (6). Working from the inside of the upper housing (23), insert the pin (6) into the small center hole. Push the pin all the way in, so it is flush with the surface of the housing.

4.

5.

Place the lower housing (22) in a vise. Position the upper housing (23) so the boss (marked RESET) is oriented as shown, and the four holes are aligned with the holes in the diaphragm (27) and lower housing (22). Assemble the two housings using the four screws (9) and lockwashers (I). Using a 10 mm socket wrench, torque to 50-70 in-lb (5.6-7.9 N.m).

Lubricate the o-ring (4*) and install it on the push pin

(15). Install the valve poppet (14,) on the barbed end of the push pin. Insert these parts into the cen- ter hole of the upper housing (23), with the poppet

(14) facing outward.

6.

7.

Install the spring (Ii*) in the upper housing (23) and seat it on the poppet (14). Install the gasket (IO*) on the spring retainer cap (25). Apply thread sealant to the threads of the retainer cap. Screw the cap into the housing using an 11/16” socket wrench, and torque to 50-70 in-lb (5.6-7.9 N.m).

Install the gasket (13*) into the lower housing (22), making sure it seats on the inside shoulder. a. Lubricate the two o-rings (5*, 7*). Install the larger o-ring (5*) in the outside groove of the valve body

(I@, and the smaller o-ring (7*) in the inside groove.

Slide the valve body into the lower housing (22), with the end holding the o-rings facing intd the housing. Use a brass rod and mallet (or a press) to seat the valve body securely in the housing.

9. Install the two o-rings (6*, 36’) in the grooves of the piston (16). Slide the piston into the valve body (16), with the narrow end facing inward. Push the piston into the valve body as far as it will go.

10. Turn the adjustment screw (21) all the way counter- clockwise, then install it and the stem guide (17) in the lower housing (22). Use a 1” crow’s-foot to torque the guide to 20-30 R-lb (27-41 N.m). so its shoulder is flush with the surface of the housing.

11. Screw the adapter (34) into the valve outlet. Rein- stall the runaway valve inthe air line. Adjust and test the valve as described on page 4.

PARTS DRAWING AND LIST

Model 224-040, Series A

Includes items l-36

DESCRIPTION

3

4 z

7

:

:

:

Ei::

10

::

::

15

103-962

104-007*

104-010*

105-399*

105~400*

150451’

166-601’

169-216*

176-671

LOCKWASHER. spring; l/4”

PIN. spring, straight

SCRMI, machine, pan hd;

1032 unf-2a; 0.312” (7.9 mm) long

O-RING; bun&N

O-RING; buna-N

O-RING; nitrile

O-RING; buna-N

PIN, dowel

SCREW. cao. hex hd: M6 x 1:

20 mm lbnrj'

GASKET: copper

SPRING, compression

PUSHBUTTON

GASKET; PTFE

POPPET valve

PIN, push

BODY, valve

;,UIDIDkstem ;;

::

::

$Z

24

;:

::

34

36 l

1 ;g::;:

166-714

HOUSING. valve

NEEDLE, valve

SCREW, adjustment

HOUSING, valve, lower

HOUSING, valve, upper

NUT, {am, hex; Q/4-32 un-2b

;;“f;prina;tatner

167-545

167-549

224-945*

166-l

160-327

111-027’

NEEDLE, valve

O-RING

ADAPTER, swivel;

3/4 npt(m) x 3/4 npsm(fJ

O-RING; buneN included in Repair Kit 224-937.

QN

SEALANT AND

TORQUETO

5070 In-lb j”

/ m -AIR OUTLET

AIR INLET

17

TORQUE TO

20-30 n-lb

(27-41 N.m)

\

24

308-201 7

DIMENSIONAL DRAWING

I t- I rrrr

11111

314 NM(F) INLET

\

TECHNICAL DATA

Maximum air input pressure

Air pressure range

Airvolume range

................

............

Air inlet .....................................

............. 120 psi (8.4 bar)

20-120 psi (1.4-8.4 bar)

.5-250 cfm (0.14-7.0 m3/min)

314 notffl

Air outlet

Weight .

. . Without swivel attached: 3i4 npt(c

With swivel attached: 3/4 npsm(f)

Wilfioutswivelaffached: 2 lb 5 oz (1.05 kg);

With swivel affached: 3 lb (1.36 kg)

THE GRACO WARRANTY AND DISCLAIMERS

WARRANN

Gracowarrantsallequipmentmanufaoturedb of sale by an authorized Grace distributor tot K itand bearingitsnametobefreefromdefectsinmaterialandworkmanshiponthedate

”

Gracowill,foraperiodoftwelvemonthsfromthedateofsale,repairorreplaceanypartoftheequipmentprovendefective.Thiswarranty applies only when the equipment is installed, operated and maintained in accordance with Grace’s written recommendations.

Thiswarrantydoesnotcover,andGracoshallnotbeliablefor,anymalfunction,damageorwearcaused byfaultyinstallation,misappli- cation,abrasion,corrosion,inadequateorimpropermaintenance,negligence,acciden!.tampering,orsubstitutionofnon-Gracocom- ponent parts. NorshallGraco beliableformalfunction,damageorwearcaused bythetncompatibrlitywithGracoequipment tures,accessories,equipmentormaterialsnotsuppliedbyGraco,ortheimproperdesign,manufacture,installation,operationormain- tenance of structures, accessories, equipment or materials not supplied by Graoo. ofstruc-

This warranty is conditioned upon the prepaid return of the equipment claimed to be defectiveto an authorized Grace verificationoftheclaim.Iftheclaimeddefectisver%ed,Gracowillrepairorreplacefreeofchar eanydefectivepatis.Theequipmentwiil be returned tothe original purohasertransportatlon prepaid. If inspection ofthe equipment 3 08s not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor and distributor for transportation.

DISCLAIMERS AND LIMITATIONS

THETERMSOFTnlSWARRANMCONS~PURGHASER’SSOLEANDWCLUSNEREMEDYANDAREINUEUOFANYOTHERWARRANTlES

(EXPRESS OR IMPUED). INCLUDING WARRANTYOF MERCHANTABILRYOR WARRANTYOF FITNESS FOR A PARTICULAR PURPOSE, AND OF

ANY NON-CONTRACTUAL LiABILtTIES, INCLUDING PRODUCT LIABILITIES, BASED ON NEGUGENCE OR STRICT UABIUTY. EVERY FORM OF

LIABILITY FOR DIRECT. SPECIAL OR CONSEQUENTtAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED. IN NO CASE SHALL

GRACO’SLlABlUNEXCEEOTHEAMOUNTOFTHEPURCHASEPRICE.ANYACTlONFORBREACHOFWARRANNMUSTBEBROUGHTWlTHlN

MI0 (2) YEARS OFTHE DATE OF SALE.

EQUIPMENT NOT COVERED BY GRACO WARRANN

GFiACO

POSE, WITH RESPECTTOACCESSORIES, ECUIPMENT, MATERIALS, OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These itemssold. butnotmanufacturedbyGraco(suchaselectricmotor,switches. hose,etc.)aresubjecttothewarranty,ifany,oftheirmanu- facturer. Graoo will provide purchaser with reasonable assistance in making any claim tor breach of these warranttes.

IMPORTANT PHONE NUMBERS

TO PLACE AN ORDER, contact your Grace distributor, or call this number to identify the distributor closest to you:

1-800-329-0211 Toll Free

FOR TECHNICAL ASSISTANCE, service repair information or assistance regarding the application of Grace equipment: l-900-9439339 Toll Free

Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)

Subsidiary and Affiliate Companies: Canada: England; Switzerland; France; Germany; Hong Kong; Japan; Korea

GRACO INC. RO. BOX 1441 MINNEAPOLIS, MN 55440-1441

PRINTED IN U.S.A. 30820, es2