Graco Airgard 224-040 Operation manual

INSTRUCTIONS-PARTS LIST. 308-201
0- Rev A
This manual contains IMPORTANT
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
AIRGARD"
Pump Runaway Valve
120 psi (8.4 bar) kXlMUM AIR INLET PRESSURE
w
Model 224-040, Series A
TABLE OF CONTENTS
Warnings.. ................................. .2
Installation ...............................
2,3
Troubleshooting.. .5
Operation .4
Service .................................... .6
Parts Drawing and List ....................... .7
Dimensional Drawing ............... Back Cover
Technical Data ..................... Back Cover
Graco Toll-Free Phone Numbers Back Cover
Warranty Back Cover
..................................
...........................
..........................
.....
GRACO INC. P.0. BOX 1441 MINNEAPOLIS, MN 55440-1441
0 COPYRIGHT 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.
CHECK all equipment regularly and repair or replace worn or
damaged parts immediately.
Alwayswearprotectiveeyewear,gloves,clothingandrespirator
as recommended by the fluid and solvent manufacturer.
Alwaysfollowthe Pressure Relief Procedureinyourseparate
pump manual, before checking, clearing, cleaning, flushing or
servicing any part of the system.
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 the maximum air inlet pressure stated on
your pump.
DONOTexceedthemaximumworkingpressureofanycompo-
nent or accessory used in the system.
Pressure Relief Procedure
To reduce the risk of serious injury, includin injury from
moving parts, alwaysfollowthisprocedurew 3, eneveryou
are servicing the runaway valve.
1. Follow the Pressure Relief Procedure in your sepa-
rate pump manual.
2. Shut off the main air shutoff valve.
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.
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.
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.
2 308-201
Installing the Runaway Valve on King’“, Bulldoge,
and Senatore Motors
DetailAof 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.
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.
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 volume ofairpassing through
the port will be low.
When no remote sensor is being used, this port is
plugged with a screw (3).

TYPICAL INSTALLATIONS
c
/
KEY
A Air Line Filter
C
B Main Air Shutoff Valve
Bleed-Type Master
Air Valve
D (required, for pump)
E
Pump Runaway Valve
F
Air Manifold
Air Regulator
Q Runaway Valve Swivel (supplied)
RECOMMENDED ADAPTERS
175-013 Nipple: 314 npt
157-191 Reducer: 314 npt x 112 npt
160427 Swivel Adapter;
314 npt(m)
x 314 npsm(f)
DETAIL
B (WALL-MOUNTED DETAIL C (CART-MOUNTED
B PRESIDENT AIR MOTOR)
MAIN AIR
LIN
Fig 1
01267
308-201 3

CAUSES OF A RUNAWAY PUMP
speed, which can result in serious damage to the pump
Pump runaway refers to a rapid acceleration in pump
which can cause pump runaway are:
parts caused by overheating and scoring. Conditions
The fluid supply container is empty, or the fluid supply
has been interrupted.
The pump is cavitating, which means that it has lost its
prime because an air pocket has formed around the
pump intake. This happens most frequently with high-
ly viscous fluids.
Afluid hose downstream from the pump has ruptured,
resulting in an increased pump cycle rate.
NOTE: The runaway valve may also trip if changes to
the system result in an increased cycle rate. For
example,
if you increase the number of gun
drops, you should readjust the valve to account
for the increased cycle.rate.
When in a runaway condition, the pump requires much
valve senses this rapid increase in the volume of air be-
more air than during normal operation. The runaway
ing .used and greatly reduces the air flow, slowing the
pump to a crawl.
NOTE: The sudden surge of air when starting the pump
may cause the valve to trip. Turn on the air slow-
ly, or readjust the valve.
ADJUSTING THE VALVE
1. Loosen the adjustment locknut (24). See Fig 2.
2. Check that the T-handle (2) 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
(F), and the bleed-type master air valve
(C). See Fig 1.
counterclockwise.
NOTE A faint hissing sound from the runaway valve is
from the poppet vent (H) during operation.
normal. The valve vents a small amount of air
5.
6.
Adjust the pump to the desired regulated air pres-
sure and cycle rate.
Turn the T-handle
(2) clockwise until the runaway
valve trips. Press and hold the RESETvalve
(R); you
will feel pressure on the RESET valve. Turn the han-
turns) until pressure on the RESET valve decreases.
die (2) counterclockwise (approximately
1 to 5
Release the RESET valve.
NOTE: At low pressure or a slow cycle rate, perform
til you feel a slight pressure pushing on the RE-
step 6, then turn theT-handle (2) clockwise un-
counterclockwise distance
in step 6.) This may
SET valve (R). (Turn it approximately half the
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. The
runaway valve should trip. Start the pump by pressing
the RESET valve
(R) and holding it in for 5 seconds.
RESETTING THE VALVE
1. Determine the condition that caused the runaway
valve to trip. Correct the condition.
2. If the air was shut
off, turn it back on slowly. A sud-
den surge of air will cause the runaway valve to trip.
3. Press the RESET valve (R) and hold it in.for 5 se-
conds. The pump should restart.
NOTE: In some installations, particularly where there is
the air supply to reset the valve.
low air volume, it may be necessary to turn off
2
Fig 2
01263
4 308-201

TROUBLESHOOTING CHART
I PROBLEM I CAUSE I SOLUTION
Valve does not slow down
pump when
It should;
pump runs away
vent when air supply is
Constant blast
of air from
turned on.
Valve shuts down for no
apparent reason
Valvedoesnotresetwhen
RESET valve is pressed
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 effect.)
Replace the diaphragm. See page 6.
Disassemble and clean valve. Replace O-rings. Piston is stuck.
speed to decrease. Readjust valve and test.
See page 4. Decreased air pressure has caused pump
See page 6.
Poppet valve (11, 14, 15) is stuck closed.
Disassemble and clean poppet valve.
See page 6. Poppet valve (1 1, 14, 15) is stuck open.
Disassemble and clean poppet valve.
See page 6.
Increased air pressure has caused pump
Readjust valve and
test. See page 4.
speed to increase.
Interrupted or exhausted fluid supply. Check fluid supply and ensure that
it remains constant.
Valve is not adjusted properly.
Press
RESET valve.
Air supply was turned on
too quickly.
Check and repair.
See page 6.
Defective poppet valve.
Check for properly adjusted fluid outlet pressure.
Decreased pump outlet pressure.
Readjust valve and test.
See page 4.
, Air leaking around TEST valve. Replace TEST valve.
~ Piston is stuck; no air is escaping from vent. Disassemble and clean runaway valve. See page 6.
Alr blowing from poppet vent. Remove
RESET valve. Clean needle and seat area.
Valve is not adjusted properly. Readjust valve and test.
See page 4.
See page 6.
I
1
Poppet vent hole plugged. I Disassemble and clean poppet valve. See 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-
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.
a.
Using an 1 l/16” socket wrench, loosen but do not
remove the cap (25) from the upper housing (23).
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.
10,
11.
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).
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.
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
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*).
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.
2.
3.
4.
5.
6.
7.
a.
9.
Place the upper housing (23) in a vise. Install the RE-
SET valve In the upper housing. Tighten the valve
housing (19) to secure.
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.
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.
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.
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.
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.
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
: : Ei::
3 103-962
4 104-007*
z 104-010*
105-399*
7 105~400*
: 105-402111.667
10 150451’
:: 156-916’156-920
:: 166-601’
169-216*
15 176-671
;; 166-706166-707
:: 1 ;g::;:
:: 166-711166710
$Z 166-714166-713
24 167-545
;: 167-549
224-945*
:: 166-l15762602
34 160-327
36 111-027’
DESCRIPTION QN
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;
POPPET valve
PIN, push
BODY, valve
;,UIDIDkstem
HOUSING. valve
NEEDLE, valve
SCREW, adjustment
HOUSING, valve, lower
HOUSING, valve, upper
NUT, {am, hex; Q/4-32 un-2b
;;“f;prina;tatner
NEEDLE, valve
O-RING
ADAPTER, swivel;
3/4 npt(m) x 3/4 npsm(fJ
O-RING; buneN
l included in Repair Kit 224-937.
SEALANT AND
TORQUETO
5070 In-lb
j”
17
TORQUE TO
20-30 n-lb
(27-41 N.m)
\
24
/ m -AIR OUTLET
AIR INLET
308-201 7
PTFE

DIMENSIONAL DRAWING TECHNICAL DATA
I
t-
\
I
rrrr
11111
314NM(F) INLET
Maximum air input pressure ............. 120 psi (8.4 bar)
Air pressure range ................ 20-120 psi (1.4-8.4 bar)
Airvolume range ............ .5-250 cfm (0.14-7.0 m3/min)
Air inlet ..................................... 314 notffl
Air outlet . . Without swivel attached: 3i4 npt(c
With swivel attached: 3/4 npsm(f)
Weight . 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 distributortot K ”
itand bearingitsnametobefreefromdefectsinmaterialandworkmanshiponthedate
e ongmal purchaser for use. As purchaser’s sole remedy for breach of this warranty,
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 ofstruc-
tures,accessories,equipmentormaterialsnotsuppliedbyGraco,ortheimproperdesign,manufacture,installation,operationormain-
tenance of structures, accessories, equipment or materials not supplied by Graoo.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defectiveto an authorized Grace distributor for
verificationoftheclaim.Iftheclaimeddefectisver%ed,Gracowillrepairorreplacefreeofchar eanydefectivepatis.Theequipmentwiil
be returned tothe original purohasertransportatlon prepaid. Ifinspection ofthe equipment 308s not disclose any defect inmaterial or
workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor and transportation.
DISCLAIMERS AND LIMITATIONS
THETERMSOFTnlSWARRANMCONS~PURGHASER’SSOLEANDWCLUSNEREMEDYANDAREINUEUOFANYOTHERWARRANTlES
(EXPRESSOR IMPUED). INCLUDINGWARRANTYOFMERCHANTABILRYORWARRANTYOFFITNESSFORA PARTICULARPURPOSE,AND OF
ANY NON-CONTRACTUAL LiABILtTIES,INCLUDING PRODUCTLIABILITIES,BASEDON NEGUGENCE OR STRICTUABIUTY.EVERYFORMOF
LIABILITYFOR DIRECT.SPECIAL OR CONSEQUENTtAL DAMAGESOR LOSS IS EXPRESSLYEXCLUDED AND DENIED. IN NO CASE SHALL
GRACO’SLlABlUNEXCEEOTHEAMOUNTOFTHEPURCHASEPRICE.ANYACTlONFORBREACHOFWARRANNMUSTBEBROUGHTWlTHlN
MI0 (2) YEARSOFTHE DATEOF SALE.
EQUIPMENT NOT COVERED BY GRACO WARRANN
GFiACOMAKESNO WARRANTYAND DISCWMS AU IMPLIEDWARRANTIESOF MERCHANTABIUTYANDFITNESSFORA PARTICULARPUR-
POSE,WITHRESPECTTOACCESSORIES, ECUIPMENT,MATERIALS,ORCOMPONENTSSOLDBUTNOT MANUFACTUREDBYGRACO.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: FOR TECHNICAL ASSISTANCE, service repair information or assistance regarding the application of Grace equipment:
1-800-329-0211 Toll Free l-900-9439339 Toll Free
Factory Branches: Atlanta, Chicago, Dallas, Detroit, LosAngeles, 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
PRINTEDIN U.S.A. 30820, es2