Graco SuperCat 232721 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1998, Graco Inc. is registered to I.S. EN ISO 9001
FIXED RATIO, HIGH CAPACITY
SuperCatProportioner
Package
5000 psi (34 MPa, 345 bar) Maximum Working 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
Conforms to ANSI/UL
standard 2279
Recognized Component
EExia II A T4
98D.123370
D
Intrinsically Safe for Hazardous Locations
Class I; Division 1; Group D
U.S. Patent Pending
Model 232721 Heated
4:1 Proportioner Shown
Parts

3089252
Table of Contents
Heated Models 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manuals 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification 9. . . . . . . . . . . . . . . . . . . . . .
Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information 10. . . . . . . . . . . . . . . . . . . . . . . .
Keep the component fluid paths separate 10. . . . .
Moving the proportioner 10. . . . . . . . . . . . . . . . . . . .
Connect the main air line 11. . . . . . . . . . . . . . . . . . .
241157 Heater Kit 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Installing additional heaters 13. . . . . . . . . . . . . . . . .
240689 Feed Pump Control Kit 16. . . . . . . . . . . . . .
240690 Level Sensor Kit 16. . . . . . . . . . . . . . . . . . . .
240688 Low Pressure Sensor Kit 16. . . . . . . . . . . .
Relocate the mix manifold 17. . . . . . . . . . . . . . . . . . .
Additional guns 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground the equipment 18. . . . . . . . . . . . . . . . . . . . . .
Check grounding continuity 18. . . . . . . . . . . . . . . . . .
Fill pump throat packing nut/wet cup 19. . . . . . . . . .
Fill air lubricator 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Solvent pump siphon hose 19. . . . . . . . . . . . . . . . . .
Metal waste container 20. . . . . . . . . . . . . . . . . . . . . .
Tighten fluid line connections and fasteners 20. . .
Do a complete system flush 20. . . . . . . . . . . . . . . . .
Follow the Setup procedure 20. . . . . . . . . . . . . . . . .
General Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 21. . . . . . . . . . . . . . . . . .
Monitor the Material Supply 21. . . . . . . . . . . . . . . . .
When to Flush the System 22. . . . . . . . . . . . . . . . . .
Fluid Heaters 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Overview 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modes of Operation 24. . . . . . . . . . . . . . . . . . . . . . . .
Operator Keypad and Display 24. . . . . . . . . . . . . . .
System Schematic Panel 25. . . . . . . . . . . . . . . . . . .
Setup Mode 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual or Spray Mode 27. . . . . . . . . . . . . . . . . . . . . . . .
Using the Manual/Spray Mode Instructions 27. . . .
To Turn off an Alarm 27. . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop 27. . . . . . . . . . . . . . . . . . . . . . . . . . .
Reservoir Low Level 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 B 30. . . . . . . . . . . . . . . . . . . . . . .
Pressure Differential 30. . . . . . . . . . . . . . . . . . . . . . .
Material Usage 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Material Usage Reset 31. . . . . . . . . . . . . . . . . . . . . .
Temperature Limits 32. . . . . . . . . . . . . . . . . . . . . . . . .
Work Life Time 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Mode 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Setup Mode Instructions 34. . . . . . . . . . .
Entering Setup Mode 35. . . . . . . . . . . . . . . . . . . . . . .
Navigating Within Setup Mode 35. . . . . . . . . . . . . . .
Saving Changes – Exiting Setup Mode 35. . . . . . .
Setup Functions 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solvent Pump Cycle Total (non-resettable) 36. . . .
Solvent Usage 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amount of Solvent 38. . . . . . . . . . . . . . . . . . . . . . . . .
Select Stored Recipes 39. . . . . . . . . . . . . . . . . . . . . .
Save Recipes 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Software Revision 40. . . . . . . . . . . . . . . . . .
High Pressure A or B 41. . . . . . . . . . . . . . . . . . . . . . .
Maximum Pressure Differential 42. . . . . . . . . . . . . .
Peak Pressures Display 43. . . . . . . . . . . . . . . . . . . .
Low Pressure A or B (Optional) 44. . . . . . . . . . . . . .
Low Pressure Sensor Option 45. . . . . . . . . . . . . . . .
Premier Pump Cycle Total (non-resettable) 46. . . .
Material B Usage 47. . . . . . . . . . . . . . . . . . . . . . . . . .
Material A Usage 48. . . . . . . . . . . . . . . . . . . . . . . . . .
Feed Pump Alarm Time (Optional) 49. . . . . . . . . . .
Premier Pump Cycle Count
(Optional, non-resettable) 50. . . . . . . . . . . . . . . . . . .
Level Sensor Selection 51. . . . . . . . . . . . . . . . . . . . .
Number of Software Startups 51. . . . . . . . . . . . . . . .
Units of Measurement 52. . . . . . . . . . . . . . . . . . . . . .
Byte Code Information 52. . . . . . . . . . . . . . . . . . . . . .
Material A High Temperature Limit 53. . . . . . . . . . .
Material A Low Temperature Limit 53. . . . . . . . . . . .
Material B High Temperature Limit 54. . . . . . . . . . .
Material B Low Temperature Limit 54. . . . . . . . . . . .
Work Life Timer 55. . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Sensor (Optional) 56. . . . . . . . . . . . . .
Setting Pressure Alarm Levels 57. . . . . . . . . . . . . . . .
Recipe Chart 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

308925 3
Table of Contents
Troubleshooting 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Path and Sensor Schematic
(non-heated systems) 60. . . . . . . . . . . . . . . . . . . . . .
Fluid Path and Sensor Schematic
(heated systems) 61. . . . . . . . . . . . . . . . . . . . . . . . . .
Level Sensors 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Level Sensors 62. . . . . . . . . . . . . . . . . . . .
Feed Pumps 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feed Pump Setup Check 63. . . . . . . . . . . . . . . . . . .
High Pressure Sensors 64. . . . . . . . . . . . . . . . . . . . .
High Pressure Sensor Check 64. . . . . . . . . . . . . . . .
Low Pressure Sensors 65. . . . . . . . . . . . . . . . . . . . .
Low Pressure Sensor Check 65. . . . . . . . . . . . . . . .
Temperature Limit Sensors 66. . . . . . . . . . . . . . . . . .
Premier Pump 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Lowers 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solvent Pump 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Solenoid Check 72. . . . . . . . . . . . . . . . . . . . . . . . .
Material Usage Display Check 73. . . . . . . . . . . . . . .
Electronic Control Check 74. . . . . . . . . . . . . . . . . . . .
Continuity Checks 74. . . . . . . . . . . . . . . . . . . . . . . . .
Care of the System 76. . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the Reservoir Outlet Filters 76. . . . . . . . . . . .
Clean the Fluid Outlet Filters 77. . . . . . . . . . . . . . . .
Agitator Care 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the Static Mixer 78. . . . . . . . . . . . . . . . . . . . . .
Premier Pump Throat Packing Nut/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. . . . . .
Reinstalling Displacement Pumps A and B 81. . . .
Removing the Premier Air Motor 83. . . . . . . . . . . . .
Reinstalling the Premier Air Motor 83. . . . . . . . . . . .
Replacing the Bearings 84. . . . . . . . . . . . . . . . . . . . .
Removing the Solvent Pump 85. . . . . . . . . . . . . . . .
Removing the Mix Manifold 86. . . . . . . . . . . . . . . . .
Blinking or Blank Display 87. . . . . . . . . . . . . . . . . . . .
Replacing the Circuit Board, Keypad, System
Schematic Panel or Wire Harness 87. . . . . . . . . . . .
Replacing the Solenoid Valves 89. . . . . . . . . . . . . . .
Replacing the Sensors 90. . . . . . . . . . . . . . . . . . . . .
Power Supply Turbine Alternator Service 94. . . . . .
Parts 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heated Packages 95. . . . . . . . . . . . . . . . . . . . . . . . . .
SuperCat Proportioner 97. . . . . . . . . . . . . . . . . . . . . .
Premier Pump Assembly 102. . . . . . . . . . . . . . . . . . .
Electronic Pneumatic Control 103. . . . . . . . . . . . . . .
Solvent Pump Assembly 106. . . . . . . . . . . . . . . . . . .
Fluid Valve Control Assembly 107. . . . . . . . . . . . . . .
Frame Assembly 109. . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 114. . . . . . . . . . . . . . . . . . . .
Graco Information 114. . . . . . . . . . . . . . . . . . . . . . . . . . .
PTFEPTFEPTFE

3089254
Standard Models
Package Part No. Description Series Proportioner Pump Ratio
232096* SuperCat A Premier12 x 12 2:1
232097* SuperCat A Premier 9 x 6 3:1
232098* SuperCat A Premier 12 x 6 4:1
243467** SuperCat Basic CS APremier 12 x 12 2:1
243468** SuperCat Basic CS APremier 9 x 6 3:1
243469** SuperCat Basic CS APremier 12 x 6 4:1
243617** SuperCat Basic SST APremier 12 x 12 2:1
243618** SuperCat Basic SST APremier 9 x 6 3:1
243619** SuperCat Basic SST APremier 12 x 6 4:1
* Includes proportioner control, Premierproportioner pump, Presidentsolvent pump, two reservoirs, mixing
manifold, automatic pressure relief valves, check valves, fluid filters, 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 Models
Package Part No. Series Proportioner Part No. Ratio Heater Part No. Voltage/Amps
232713 A 232096 (12 x 12) 2:1 245863 240/16.7
232714 A 232096 (12 x 12) 2:1 245864 480/8.30
232715 A 232096 (12 x 12) 2:1 245862 200/20.0
232716 A 232096 (12 x 12) 2:1 245863 240/16.7
232717 A 232097 (9 x 6) 3:1 245863 240/16.7
232718 A 232097 (9 x 6) 3:1 245864 480/8.30
232719 A232097 (9 x 6) 3:1 245862 200/20.0
232720 A 232097 (9 x 6) 3:1 245863 240/16.7
232721 A 232098 (12 x 6) 4:1 245863 240/16.7
232722 A 232098 (12 x 6) 4:1 245864 480/8.30
232723 A232098 (12 x 6) 4:1 245862 200/20.0
232724 A 232098 (12 x 6) 4:1 245863 240/16.7
These 200V packages are only available in Asia.

308925 5
Instruction Manuals
The following instruction manuals are included with the
equipment. To maintain, service, or order parts for an
individual component, such as the proportioning pump,
refer to its instruction manual.
Description Manual No. Component
Part No.
SuperCat Installation and
Service
308925 232096 to
232098,
243467 to
243469,
243617 to
243619, and
232713 to
232724
SuperCat Operation 308875 232096 to
232098,
243467 to
243469,
243617 to
243619, and
232713 to
232724
Premier Air Motor 308213 240176
Premier Displacement
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 No.
Viscon HP Fluid Heater 309524 245862,
245863, and
245864
Air Regulator 308859 114104 and
114459
Air Filter and Air Lubricator 308169 112859 and
237212
Fluid Filter 307273 240183
Pressure Relief Valve 308547 237074
Fluid Flow Control Valve 307892 222200
Mix Manifold 308858 240225
Ball Valve 306861 240410 and
240411
Silver Plus Gun 308236 235464
Feed Pump Control Kit 308959 240689
Fluid Level Sensor Kit 308860 240690
Low Pressure Sensor Kit 308861 240688
Heater Kit 308914 241157
Temperature Sensor Kit 308927 241239

3089256
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
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the spray gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove, or 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.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 21 if the spray tip/nozzle clogs and whenever you:
are instructed to relieve pressure; stop spraying; clean, check, or service the equipment; and install
or clean the spray tip.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Do not mend or repair any part of the hose assembly.
If the hose is damaged, replace it immediately.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate fingers.
Do not operate the equipment with the air motor plates removed.
Keep your body and tools clear of any moving parts when starting or operating the equipment.

308925 7
WARNING
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in fire, explosion, electric shock, or other serious injury.
Ground the equipment and the object being sprayed. See Ground the Equipment on page 18.
The heaters are grounded through the electrical power supply.
The electric heater must be installed, operated, and serviced only by trained, qualified personnel
who fully understand the requirements stated in the heater instruction manual.
All electrical wiring must be done by trained and qualified personnel and comply with all local codes
and regulations.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Do not smoke within the spray area.
Extinguish 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 not turn on or off any light switch within the spray area while operating or if fumes are present.
Do not operate a gasoline engine within 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.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state, and national guidelines.
Always wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and
solvent manufacturer.
Graco does not manufacture or supply any of the reactive chemical components that may be used
in this equipment and is not responsible for their effects. Graco assumes no responsibility for loss,
damage, expense, or claims for personal injury or property damage, direct or consequential, arising
from the use of such chemical components.

3089258
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 5000 psi (34 MPa, 345 bar) maximum working pressure at 100 psi (0.7 MPa, 7 bar)
maximum incoming air pressure.
Do not exceed the maximum temperature rating of the lowest rated system component. This equip-
ment has a maximum temperature 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 displacement pump pressure
exceeds the maximum working pressure.
Do not touch the heater during operation; it is very hot.
Do not lift pressurized equipment.
Do not lift the equipment by the Premier air motor lift ring. See page 10 for suggestions for moving
or lifting equipment.
Use only Graco approved hoses. Do not remove hose spring guards, which help protect the hose
from rupture caused by kinks or bends near the couplings.
Route the hoses away from the 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).
Use fluids and solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

308925 9
Component Identification
KEY
8 PremierProportioning Pump
15* Reservoir
17 Mix Manifold
17c Static Mixer
20 Air Lubricator
39* Gun Fluid Hose, 50 ft. (15.25 m), 3/8 in. (9.53 mm) (not shown)
41* Gun Whip Hose, 6 ft (1.83 m)., 1/4 in. (6.35 mm)
42* Graco Silver PlusSpray Gun
44 Standard 3 Gun Manifold (out of view behind reservoir)
53* Agitator
54* Reservoir Filter
56* Reservoir Ball Valve
71 Premier Pump Air Shutoff Valve
89* President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
207 Fluid Outlet Pressure Gauges
506Fluid Heater
508Insulated Fluid Hose (shown)
C Premier Air Regulator
D Solvent Air Regulator
E Feed Pump A Air Regulator (optional)
F Feed Pump B Air Regulator (optional)
* These items are not included in the Basic Packages.
These items are only included in the Heated Packages.
8788A
Fig. 1
8
71
121
89*
15*
56*
CD
E
F
54*
53*
17
17c
44
204
202203
125e
125g
42*508(shown) or39* 41*
207
20
506

30892510
Installation
General Information
Reference numbers and letters in parentheses in
this text refer to the numbers and letters in the
illustrations.
Be sure all accessories are adequately sized and
pressure-rated to meet the system requirements.
See page 112 for dimensions.
Apply tape and sealant to pipe threads
before assembling them. Leave the first thread
uncovered to maintain electrical continuity.
Notes About Basic Units
The basic units require pressure–fed systems for
each material (A and B). Do not exceed 1000 psi (7
MPa, 70 bar), and make sure the feed system is
capable of at least twice the volume of the pump it
is supplying.
If heat is used on the feed systems, make sure the
fluid hose is capable of the heat and pressure
required. Mount the heaters on the heater bracket
as described on the following pages, making sure
they are appropriately plumbed for constant fluid
flow. Since reservoirs are not used, the circulation
feature is not available, and provisions should be
made to circulate material back to the feed source
during 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 reservoir sensors. This could
cause nuisance alarms.
Keep the Component Fluid Paths
Separate
CAUTION
Be sure to label all fluid path parts “component A” or
“component B”. Doing so prevents interchanging A
and B parts, which will contaminate the materials and
the fluid path through the equipment.
Color-coded chemically resistant tape may be used
to label 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.
Moving the Proportioner
WARNING
To avoid serious injury, do not lift the
equipment by the Premier air motor lift
ring (H–Fig. 2). It cannot support the
weight of the system.
8792A
Fig. 2
H
If moving the proportioner with a forklift, be sure it is
securely set on the forklift before lifting it.
If moving the proportioner with a crane, the propor-
tioner must be placed in a cage or other sturdy sup-
port, which fully supports the base/pallet. Do not
attach the crane hook to the Premier air motor lift
ring, or any other part of the proportioner system!
PTFEPTFEPTFE

308925 11
Installation
1. Connect the main air line.
NOTE: See Fig. 1 for all installation steps except
where otherwise directed.
Connect the main air line to the 1 in. npsm(f) inlet
of the air line filter (79) at the back of the cabinet.
See Fig. 3.
The air supply at the proportioner must be a mini-
mum of 100 psi (0.7 MPa, 7 bar) and 150 scfm
(4.2 m3/min.).
A minimum 1 in. (25.4 mm) I.D. hose is recom-
mended.
8806A
Fig. 3
79
Main Air Line
2. Optional: Install 241157 Heater Kit
NOTE: Packages 232713 through 232724 are
shipped with the 241157 Heater Kit and two Viscon
HP Fluid Heaters installed.
Kit No. 241157 is available to convert an unheated
SuperCat proportioner to the standard heated
system described on page 12. The kit includes
necessary parts to install two Viscon HP fluid
heaters on the SuperCat. Refer to manual 308914
for installation instructions.
Viscon HP heaters and feed pumps are not in-
cluded with the kit and must be ordered separately.
The heaters are available in four voltages. Specify
which voltage you desire.
Model 245863 Viscon HP 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
The Viscon HP Heaters must be
installed by a qualified electrician in
compliance with all state and local codes
and regulations, to reduce the risk of
electric shock or other serious injury
during installation or operation.
When installing in a flammable atmo-
sphere (hazardous location) refer to
Article 500 of the US National Electric Code or
other applicable agency standards to plan the
work.
Refer to the Viscon HP Heater manual (supplied
with the heater) for information on heater power
supply requirements.
Do not plug in or unplug a power cord in any area
containing flammable fluids or fumes, to avoid fire
or explosion resulting in serious injury.
Do not put flammable materials and debris on or
near the heaters. Keep the work area clean.
WARNING
COMPONENT RUPTURE HAZARD
Heat causes fluid to expand. If the
heated fluid is trapped with nowhere to
expand, it can cause component rupture.
Be sure to keep the heated fluid circulating (open
the recirculation valves). Do not install a fluid
shutoff device between the heater and the gun.

30892512
Installation
Standard Heater Configuration
Fig. 4 shows the standard heater configuration. In
this configuration, install the heaters on the recir-
culation lines between the fluid cabinet and the
reservoirs. The feed pumps supply material to the
reservoirs through the fluid heaters. Check valves
prevent backflow into the feed lines or into the fluid
cabinet.
To heat cold material in the reservoirs, 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 level, close the
recirculation valves, open the mix manifold valves
and begin spraying. New material supplied by the
feed pumps will be heated before it enters the
reservoirs.
Reservoir Proportioner Fluid Cabinet
Gun
Pump
Heater
Material
Supply
Mix Manifold
Feed
Pump
Recirculation
Line
1/2 in. Check Valves
Fig. 4
8686A
NOTE: This configuration is used both on the
A Component and on the B Component sides.

308925 13
Installation
3. Optional: Installing Additional Heaters
The heated proportioner packages include two
heaters, one for each component. If your applica-
tion requires a higher temperature than one heater
per component can achieve, the heater bracket
can accommodate two additional heaters.
Kit No. 241186 is available. Each kit includes
plumbing for one additional heater.
Connecting heaters in series allows you to spray at
a higher temperature, because the second heater
increases the fluid temperature achieved by the
first heater.
Heaters in series can also equalize temperature of
the fluid components when the ratio of A to B is
different. For example, a 4:1 ratio of A to B means
that component A flows through the heater faster
than component B, therefore the temperature of
component A will be less than component B. Using
a second or a third heater in series on the A side
will equalize the temperature of the components.
Contact your 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 the fluid flow. These configu-
rations are briefly described below. Contact your
Graco distributor for further information.
a. Option 1, for batch mode applications
(reservoirs are filled manually): This config-
uration is the same as the standard, but feed
pumps are not used. Install the heaters on the
recirculation lines between the fluid cabinet
and the reservoirs. See Fig. 5. Fill the reser-
voirs manually. To heat cold material in the
reservoirs, 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 level, close the recircula-
tion valves and open the mix manifold valves.
Spray one batch at a time, then repeat the
process.
Mix ManifoldFluid CabinetReservoir Proportioner
Gun
Heater
Pump
8683A
Fig. 5
NOTE: This configuration is used both on the
A Component and on the B Component sides.
Recirculation Line

30892514
Installation
b. Option 2, for continuous applications
when reservoirs are filled manually: In this
configuration, the maximum working pressure
of the proportioner must be derated to 4000
psi (27.6 MPa, 276 bar). See the Warning at
right. Reduce the maximum working pressure
setting in the SuperCat electronics to 4000 psi
(27.6 MPa, 276 bar) or lower (see page 41).
Install the heaters on the fluid lines between the
proportioner pump and the fluid cabinet. See Fig.
6. Also, pressure relief valves are required be-
tween the proportioner pump 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, continuous spraying is possible.
WARNING
COMPONENT RUPTURE HAZARD
Do not exceed the heater’s maximum
fluid working pressure of 4000 psi (27.6
MPa, 276 bar).
Install Part No. 237074 Pressure Relief Valves on
the fluid lines between the proportioner pump and
the fluid heaters, to prevent overpressurization
should the heaters become plugged.
Reservoir Proportioner
Fluid Cabinet Mix Manifold Gun
Heater
Pump
Pressure Relief
Valve
8684A
Fig. 6
NOTE: This configuration is used both on the
A Component and on the B Component sides.
Recirculation
Line

308925 15
Installation
Option 3, for continuous applications when
reservoirs are filled manually: Install additional
circulation pumps to create a loop from the reser-
voirs, through the circulation pumps, through the
heaters, and back to the reservoirs. See Fig. 7. Fill
the reservoirs manually. Set the heaters to the
desired temperature and circulate the 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, continuous
spraying is possible.
Reservoir Proportioner Fluid Cabinet
Mix Manifold Gun
Pump
Heater
Circulation
Pump
8685A
Fig. 7
NOTE: This configuration is used both on the
A Component and on the B Component sides.
Proportioner Fluid Cabinet
Mix Manifold Gun
Pump
Heater
Fig. 8
NOTE: This configuration is used on the basic
units (when reservoirs are not used).

30892516
Installation
4. Optional: Install the feed pumps and
the 240689 Feed Pump Control Kit.
NOTE: The 240689 Feed Pump Control Kit is
factory installed on heated proportioners 232713
through 232724. The kit includes necessary parts
to install two air regulators and dolenoids to control
the feed pumps. Refer to manual 308959 for
installation instructions.
It is recommended that the feed pumps have twice
the flow rate of the Premier production flow rate (2
GPM, 7.6 liters/min. maximum). Undersized feed
pumps can cause an alarm or cause the reservoirs
to run dry.
NOTE: Additional sensors can be purchased to
allow the control 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
proportioner. The installation of both low and full
level sensors, along with the change of the level
sensor option in setup, allows the system to be
used with manual or automatic feed with feed
pumps, without changing the sensor locations.
Refer to manual 308860 for installation instruc-
tions.
6. Optional: Install 240688 Low Pressure
Sensor Kit
This optional kit includes two low pressure sen-
sors, which attach to the reservoir outlet filters
(54). The low pressure sensors, along with a
change in setup, enable the system to detect a
plugged filter and sound an alarm.
Refer to manual 308861 for installation instruc-
tions.

308925 17
Installation
7. Optional: Remove and relocate the mix
manifold.
It may be necessary to move the mix manifold (17)
closer to the object being sprayed to reduce the
length of mixed material fluid hose. This will help
reduce material waste and may be necessary
when using materials with very short work life.
NOTE: Work life time is the amount of time that a
material can be effectively sprayed and applied to
a surface.
To remove the mix manifold from the proportioner,
disconnect the fluid lines from the mix manifold
fluid line connectors (17d). Loosen the knob (58)
and lift the panel (16) off the unit. Place the mix
manifold in the location desired. Make sure the
mounting surface can support the weight of the
manifold, any hoses connected to it, and any
stress that may be applied during operation.
Connect the fluid lines, in the length required,
between the proportioner and the mix manifold. If
using more than 50 ft. (15.25 m) of hose 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: Connect additional guns.
The standard proportioner has a three gun man-
ifold (44). See Fig. 10. Two of the 3/8 npt outlet
ports are plugged. The gun fluid hose (provided) is
connected to the bottom port.
WARNING
COMPONENT RUPTURE HAZARD
Do not install a fluid shutoff device
between the heater and the gun.
To connect additional guns, remove the plug(s)
(37) and install shut-off valve(s) (SV) on non-
heated systems only. Then install the fluid hose(s)
and gun(s). Add a shut-off valve to the gun fluid
hose that is included with the proportioner.
NOTE: Install hoses and guns in the lowest avail-
able manifold port to prevent mixed material from
solidifying in an unused area of the manifold.
Fig. 9
58
16
17
KEY
16 Panel
17 Mix Manifold
17a Mix Manifold Shutoff
Valve
17b Solvent Shutoff Valve
17c Static Mixer
17d Fluid Line Connector
58 Knob
17a
17b
17d
17c
8352A
8397A
Fig. 10
44
37
SV
1Do not install on heated systems.
See the WARNING at left.
1

30892518
Installation
9. Ground the equipment.
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding could cause static
sparking, which could cause a fire or
explosion. To reduce the risk of property
damage or serious injury, follow the
grounding instructions below.
The following grounding instructions are minimum
requirements for a system. Your system may include
other equipment or objects which must be grounded.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment. Your
system must be connected to a true earth ground.
SuperCat Proportioner:
Loosen the grounding lug locknut (X) and washer
(Y) on the Premier pump. See Fig. 11. Insert one
end of a 12 ga. (1.5 mm) minimum ground wire
(W) into the slot in grounding lug (Z) and tighten
the locknut securely. Connect the other end of the
ground wire to a true earth ground.
Fig. 11
X
Y
W
Z
0864
KEY
W Ground Wire
X Locknut
Y Washer
Z Grounding
Lug
Fluid Heater (if present): refer to the heater
manual, supplied.
Air hoses: use only electrically conductive hoses
with a maximum of 500 feet (150 m) 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 to a prop-
erly grounded fluid hose and pump.
Fluid supply container: follow your local code.
Object being sprayed: follow your local code.
Solvent pails used when flushing: follow your
local code. Use only metal pails, which are conduc-
tive, placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continuity.
Waste containers placed under the fluid drain
valves: use only metal pails, which are conductive.
To maintain grounding continuity when flush-
ing or relieving pressure, always hold a metal
part of the spray gun firmly to the side of a
grounded metal pail, then trigger the gun.
10.Check grounding continuity.
Have a qualified electrician check the grounding
continuity between the pump and the true earth
ground. The resistance must be less than 25
ohms. If the resistance is greater than 25 ohms,
the pump ground wire may not be properly con-
nected, an internal ground wire connection may be
loose, or a different ground site may be required.
Do not operate the system until the problem is
corrected.

308925 19
Installation
11. Fill the pump throat packing nut/wet
cup (K).
Keep the pump throat packing nut/wet cup (K)
filled with Graco throat seal liquid (TSL) to help
prevent fluid from drying on the displacement rod
and damaging the pump packings. See Fig. 12.
Refer to the procedure 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
Fig. 12
KEY
K Pump Throat Packing Nut/Wet Cup
04373
12.Fill the air lubricator (20–Fig. 1 on page
9) with Graco motor oil, part no.
202659. Refer to Manual 308169.
13.Place the solvent pump siphon hose
(610) into the solvent container.
8791A
Fig. 13
KEY
610 Solvent Pump Siphon Hose
610

30892520
Installation
14.Place a metal waste container (49)
under the pressure relief (203) and
fluid drain (204) valves.
WARNING
INJECTION HAZARD
Fluid emitted from the automatic pressure relief
valves and fluid drain valves may be at high pres-
sures. To reduce the risk of serious injury from fluid
injection or fluid splashing, make sure the container
used to catch the drainage can contain a sudden
spurt of pressurized fluid.
FIRE AND EXPLOSION HAZARD
Use a metal waste container to maintain grounding
continuity.
Route and secure the fluid tubes (242) into the
containers (49). See Fig. 14. Use waste containers
that are large enough for the entire day’s operation
or have additional containers available.
Route the tubes (240) into the beakers (228).
NOTE: Over-pressurization may occur if there is a
fluid line clog downstream from the pressure relief
valve or if any other condition 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 psi (44.4
MPa, 448 bar). This helps avoid component rup-
ture and serious injury.
15.Tighten the fluid line connections and
fasteners.
Connections may have loosened during shipment.
Check and tighten as needed.
8788A
Fig. 14
49
204
242
228
203
KEY
49 Waste Container
203 Automatic Pressure
Relief Valve
204 Fluid Drain Valve
228 Beakers
240 Fluid Tube
242 Fluid Tube
240
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, pressurize the
system at low pressure and check for leaking
fittings/connectors before operating the system at
high pressure.
16.Do a complete system flush.
The system was tested with light-weight oil, which
is left in to protect parts. Flush the system before
using it with a solvent compatible with your dis-
pense material. Follow the Complete System
Flush procedure in the Operation Manual 308875,
supplied.
17.Follow the Setup procedure. See
page 34.