Graco 205612 User manual

306715
Rev. G
Supersedes Rev. F
First choice when
quality counts.t
06479
06480
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Stainless Steel, Air-Operated
Dispensing Valve
3000 psi (21.0 MPa, 210 bar) Maximum Working Pressure
Model 205612, Series B
Without seat or fluid needle
Model 205435
Includes Dispensing Valve 205612, chrome-plated
tapered fluid needle, and seat.
Model 207440, Series D
Includes chrome-plated fluid needle with tungsten
carbide ball, and seat.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Parts
Contents

2 306715
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 6. . . . . . . . . . . . . . . . . . . . . . . . .
Ventilate the Dispense Booth 6. . . . . . . . . . . . . . . . .
Mount Valve 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect the Air Lines 6. . . . . . . . . . . . . . . . . . . . . . .
Connect the Fluid Lines 7. . . . . . . . . . . . . . . . . . . . . .
System Accessories 7. . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Settings and Adjustments 8. . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 8. . . . . . . . . . . . . . . . . . .
Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the Dispensing Valve Daily 9. . . . . . . . . . . . .
Flushing 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Needle, Seat and Packings 11. . . . . . . . . . . . . . . . .
Air Piston, Spring and Seals 11. . . . . . . . . . . . . . . . .
Packing Configurations 11. . . . . . . . . . . . . . . . . . . . .
Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 205435 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 205612, Series B 12. . . . . . . . . . . . . . . . . . . .
Model 207440, Series D 13. . . . . . . . . . . . . . . . . . . .
Manual Change Summary 13. . . . . . . . . . . . . . . . . . . . .
Dimensions 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 16. . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 16. . . . . . . . . . . . . . . . . . . . . . . .
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
corresponding instructions.

3306715
WARNING
INJECTION HAZARD
Spray from the valve, hose leaks, or ruptured components can inject fluid into your body and cause an
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause a serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
DDo not point the dispensing valve at anyone or at any part of the body.
DDo not put hand or fingers over the nozzle.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DDo not “blow back” fluid; this is not an air spray system.
DFollow the Pressure Relief Procedure on page 8 whenever you: are instructed to relieve pres-
sure; stop dispensing; clean, check, or service the equipment; and install or clean the nozzle.
DTighten all the 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.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
DKnow the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
DStore hazardous fluid in an approved container. Dispose of the hazardous fluid according to all
local, state, and national guidelines.
DWear appropriate protective clothing, gloves, eyewear, and respirator.

4 306715
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire or explosion and serious injury.
DGround the equipment and the object being sprayed. See Grounding on page 5.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being
dispensed.
DExtinguish all the open flames or pilot lights in the dispensing area.
DElectrically disconnect all the equipment in the dispensing area.
DKeep the dispensing area free of debris, including solvent, rags, and gasoline.
DDo not turn on or off any light switch in the dispensing area while operating or if fumes are present.
DDo not smoke in the dispensing area.
DDo not operate a gasoline engine in the dispensing area.
DIf there is any static sparking while using the equipment, stop dispensing 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 a serious injury.
DThis equipment is for professional use only.
DRead all the instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. These
dispensing valves have a 3000 psi (21.0 MPa, 210 bar) Maximum Working Pressure.
DUse fluids that are compatible with the equipment wetted parts. See the Technical Data section of
all the equipment manuals. Read the fluid manufacturer’s warnings.
DRoute the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).
DWear hearing protection when operating this equipment.
DComply with all applicable local, state, and national fire, electrical, and other safety regulations.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment.

5306715
Installation
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating, ground the system as
explained below. Also read the section
FIRE AND EXPLOSION HAZARD on
page 4.
To reduce the risk of static sparking, ground the pump
and all other components used or located in the dis-
pensing area. Check your local electrical code for
detailed instructions for your area and type of equip-
ment and be sure to ground all of these components.
DPump: use a ground wire and clamp as instructed
in your separate pump instruction manual.
DAir compressors and hydraulic power supplies:
ground according to the manufacturer’s recommen-
dations.
DAir and fluid hoses: use only electrically conductive
hoses with a maximum of 500 feet (150 m) com-
bined hose length to ensure grounding continuity.
DDispensing valve: obtain grounding through con-
nection to a properly grounded fluid hose and
pump.
DFluid supply container: according to local code.
DAll solvent pails used when flushing, according to
local code. Use only metal pails, which are conduc-
tive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter-
rupts grounding continuity.

6 306715
Installation
Key
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
Bleed-type Master Air Valve
Air Regulator
Supply Pump
Fluid Drain Valve
Air Line
Fluid Line
Solenoid Valve
Control Box
Dispensing Valve
Sensing Device
Back Pressure Valve
Circulation Return Line (optional)
Air Line Filter
Fluid Pressure Regulator
Fluid Filter
Pump Runaway Valve
Air Line Lubricator
Typical Installation
06481
N
A
S
BT
C
R
DM
L
PE
K
H
G
J
E
F
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor.
The Typical Installation drawing above is only a
guide for selecting required and optional accessories
for an automatic dispensing system. Contact your
Graco distributor for assistance in designing a system
to meet your particular needs.
Ventilate the Dispense Booth
WARNING
To prevent hazardous concentrations of toxic
and/or flammable vapors, use this valve only in a
properly ventilated dispense booth. Never operate
the dispensing valve unless ventilation fans are
operating.
Mount Valve
Mount the valve on a 0.50 in. (12.7 mm) diameter rod
(Y) on a mounting fixture or a dispensing machine.
See Fig. 1 and the Typical Installation. Models
205435 and 205612 are supplied with a clamping
screw for mounting. For Model 207440, order the
clamping screw separately (Part No. 205355).
Connect the Air Lines
Clean all lines and connections of dirt, burrs, etc. and
blow them out with clean air before connecting them to
the system. The air supply line (E) should contain an
air filter (N) to remove harmful dirt and moisture from
the compressed air.
Use a normally closed 3-way air solenoid valve (G) to
control the dispensing valve (J). Attach a grounded air
supply line (E) from the 3-way valve to the 1/4
npsm(m) air inlet adapter (7) of the dispensing valve.
See Fig. 1.
Fig. 1
06482
Y
E
7
X
19
Model 207440 Shown
F

7306715
Installation
Connect the Fluid Lines
Connect a grounded fluid line (F) from the pump to the
fluid inlet adapter (19) of the dispensing valve. You
should install a fluid pressure regulator (P) to control
fluid pressure to the dispensing valve. A regulator
enables you to control fluid pressure more accurately
than by regulating air pressure to the pump.
Install a fluid filter (R) to remove particles and sedi-
ment which may clog the nozzle.
In a circulating system, remove the plug (4) from the
circulation port (X). Connect a return line (M) from the
circulating port to the back pressure valve. The back
pressure valve ensures regulated pressure to all
dispensing valves in the system.
System Accessories
WARNING
Two accessories are required in your system: a
bleed-type master air valve (A) and a fluid drain
valve (D). These accessories help reduce the risk
of serious injury including fluid injection, splashing
in the eyes or on the skin, and injury from moving
parts if you are adjusting or repairing the pump.
The bleed-type master air valve is required only
with air-powered pumps. It relieves air trapped
between this valve and the pump after the air
regulator is shut off. Trapped air can cause the
pump to cycle unexpectedly. Locate the valve close
to the pump.
The fluid drain valve assists in relieving fluid pres-
sure in the displacement pump, hose, and dispens-
ing valve; triggering the valve to relieve pressure
may not be sufficient.

8 306715
Operation
Settings and Adjustments
Before each day’s operation, lubricate the exposed
portion of the needle (22) and the piston (16) with a
lubricant compatible with the fluid being dispensed.
After lubrication, cover the exposed portions of the
needle and piston with a piece of plastic to prevent
fluid buildup on these parts. Any buildup could damage
the valve packing (9 or 20). See Fig. 3.
Set the actuating air to at least 50 psi (345 kPa, 3.4
bar) and start the pump. Adjust the pump speed and
pressure to obtain the desired flow rate. Always use
the lowest pump speed necessary to get the results
you want.
To decrease needle travel, turn the adjusting screw
(12) clockwise; to increase, turn counterclockwise. If
the valve leaks from the outlet after it is closed, turn
the adjusting screw clockwise until the valve stops
leaking.
In a circulating system, adjust the back pressure valve
to provide constant system back pressure for all dis-
pensing valves while maintaining the proper pressure
for fluid circulation. See the Typical Installation on
page 6.
Fig. 2
06482
16
22
Model 207440 Shown
1
1
Oil Daily
12
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause
serious injury. To reduce the risk of an
injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
Dare instructed to relieve the pressure,
Dstop dispensing,
Dcheck or service any of the system equipment,
Dor install or clean the nozzle.
1. Shut off the power to the pump.
2. Close the bleed-type master air valve (required
with air powered pumps).
3. Actuate the dispensing valve to relieve pressure.
4. Open the pump drain valve (required in your
system) to help relieve fluid pressure in the dis-
placement pump. Actuating the dispensing valve to
relieve pressure may not be sufficient. Have a
container ready to catch the drainage.
5. Leave the drain valve(s) open until you are ready
to dispense again.
If you suspect that the dispensing valve or hose is
completely clogged, or that pressure has not been fully
relieved after following the steps above, very slowly
loosen the hose end coupling and relieve pressure
gradually, then loosen completely. Now clear the valve
or hose.

9306715
Maintenance
Clean the Dispensing Valve Daily
CAUTION
Be sure the solvent you use is compatible with the
fluid being dispensed, to avoid clogging the valve’s
fluid passages.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
An important part of the care and maintenance of your
automatic dispensing valve is proper flushing. Flush
the valve daily with a compatible solvent until all traces
of fluid are removed from the valve passages. Relieve
the pressure before flushing.
Clean the outside surfaces of the valve by wiping with
a soft cloth dampened with a compatible solvent.
CAUTION
Never immerse the entire dispensing valve in sol-
vent. Immersing in solvent removes lubricants and
tends to damage packings.
To remove a hardened particle from the orifice, blow
air through the orifice from the front.
Flushing
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Before flushing, be sure the entire system and flushing
pails are properly grounded. Refer to Grounding on
page 5. Relieve the pressure and remove the nozzle
from the dispensing valve. Always use the lowest
possible fluid pressure, and maintain firm metal-to-
metal contact between the dispensing valve and the
pail during flushing to reduce the risk of fluid injection
injury, static sparking, and splashing.
Start the pump and flush the system with a compatible
solvent as explained in the instructions for your pump.
Check the system under pressure for leaks; if any are
found, relieve the pressure and repair the leaks.
Pressurize the system again and make sure the leak-
ing has stopped.

10 306715
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Before servicing this equipment always make sure to
relieve the pressure.
NOTE: Check all possible causes and solutions
before disassembling.
Problem Cause Solution
Uneven dispensing pattern. Fluid pressure too low. Increase air pressure to pump, or adjust
fluid pressure regulator.
Valve will not stop dispensing. Fluid pressure too high. Reduce air pressure to pump, or adjust
fluid pressure regulator.
Fluid needle binding. Clean, repair.
Piston packing binding. Repair.
Obstructed or worn needle or seat. Clean or replace.
Valve will not dispense. Pump not operating. Refer to separate pump manual.
Fluid line clogged. Clear.
Fluid valve closed. Open.
Clogged orifice or needle seat. Clean.
No trigger or actuator pressure. Check, clean all lines.
Worn or dry piston packings. Replace.