INSTRUCTIONS-PARTS LIST
308–287
Rev. C
Supersedes Rev. B
and PCN C
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
First choice when
quality counts.t
INSTRUCTIONS
PROt Pulse
Electronic Volumetric Flow Meter
For use with Plural Component Precision Mixing Systems
This meter is designed to be used in a Class I, Group D hazardous environment
2800 psi (19.6 MPa, 196 bar) Maximum Working Fluid Pressure
50 psi (350 kPa, 3.5 bar) Maximum Working AirPressure
Part No. 235–402, Series A
Flow Meter with 0.1 cc per tooth fluid volume flow
Model 235–403, Series A
Flow Meter with 0.4 cc per tooth fluid volume flow
NOTE: See the Accessories section to order Fiber
-
Optic Cables and to order the Fluid Manifold.
U.S. and Foreign Patents Pending
01847
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1993, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
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WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
INSTRUCTIONS
in a serious injury
.
D
D
D
This equipment is for professional use only.
Read all the 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.
D
D
D
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the 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 2800 psi (19.6 MPa, 196 bar) maximum working pressure.
-
D
D
D
Use fluids that are compatible with the equipment wetted parts. See the
all the equipment manuals. Read the fluid manufacturer s warnings.
Technical Data section of
’
Route 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).
Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
308–287
3
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Installation
L
M
E
R
S
G
2
A
B
C
D
NON-HAZARDOUS AREA
HAZARDOUS AREA
H
F
N
P
1
A
B
C
D
E
J
K
KEY
A
B
Air Supply Line
Bleed-Type Air Supply Line
Shut-off Valve (required)
Air Line Filter
Air Line Lubricator
Air Line Regulator
Pump
C
D
E
F
G
H
J
K
L
M
N
P
R
S
Fiber Optic Cable
Flow Meter
Fluid Supply Line
Fluid Supply
Main Power Switch
Pendant
Pump Grounding Wire (required)
Fluid Manifold
115V 60 Hz Electrical Supply
Controller
01848
The PRO Pulse Volumetric Flow Meter is designed to
detect the pulses induced on a magnetic sensor each
time a gear tooth passes by the sensor. A specific
volume of fluid flows through the meter with each gear
tooth rotation. See the front cover for the specific fluid
The Typical Installation shown above is only a guide
for selecting and installing the flow meter. For assis
tance in designing a particular type and size system for
your application, contact your Graco representative.
-
volume flow of your meter
.
Install the air line accessories in the order shown in the
Typical Installation, using adapters as necessary.
Installing the System
Connect the air line to the Flow Meter by pressing the
front ferrule (D) and back ferrule (C) onto the tubing
(A). See Fig. 1. Press the assembly into the fitting (E)
and tighten the nut (A). Connect the fiber optic cables
by pressing the front ferrule (L) and back ferrule (K)
onto the cable (G).
WARNING
To help reduce the risk of serious injury, including
splashing in the eyes or on the skin, the bleed-type
1
air shut-off valve (B ) must be installed in the
system to relieve 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.
The maximum fiver optic cable length is 100 ft (30.5
m) with two splices. See Accessories on page 14 to
order cables.
4
308–287
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Installation
KEY
Fiber Optic
A
B
C
D
E
F
G
H
J
Tubing, 1/4” OD
Sender
1
Nut (nylon)
Fiber Optic
Ferrule, back (nylon)
Ferrule, front (nylon)
Air Inlet Fitting
Electrical Chassis
Fiber Optic Cables
Sender
2
F
Power Indicator
Light (Yellow)
L
K
Gear Housing Assy
.
J
Nut (aluminum)
Flow Indicator
Light (Green)
K
L
Ferrule, back (aluminum)
Ferrule, front (aluminum)
E
H
D
C
G
B
A
01849
Fig. 1
Check the Electrical Grounding
Electrical
Chassis
WARNING
Proper electrical grounding of your system is
essential when used with flammable or combustible
liquids. For you safety, read the warning section
FIRE, EXPLOSION, AND ELECTRIC SHOCK
HAZARD on page 2.
Digital
Voltage
Meter
Have a qualified electrician check the electrical
grounding continuity between the flow meter electrical
chassis and a true earth ground as shown in Fig. 2. If
the resistance is greater than 25 ohms, check the
mounting or add a ground strap to the chassis.
True Earth Ground
01850
Fig. 2
308–287
5
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Operation
Pressure Relief Procedure
System Operating Checklist
Check the following list daily, before starting to operate
the system, to help ensure you of safe, efficient opera
tion.
-
WARNING
INJECTION HAZARD
Fluid under high pressure can be in
jected through the skin and cause
D
D
Be sure all operators are properly trained and
qualified to safely operate your system.
-
serious injury. To reduce the risk of an
injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
Be sure all operators are trained how to properly
and completely relieve system pressure according
to the Pressure Relief Procedure, at left.
D
D
D
are instructed to relieve the pressure,
stop operating,
D
D
D
Be sure the system is thoroughly grounded. See
FIRE, EXPLOSION, AND ELECTRIC SHOCK
HAZARD, page 2, and Check the Electrical
Grounding, page 5.
or check or service any of the system equip
ment.
-
Be sure the operator and all persons entering the
installation site are properly grounded by wearing
shoes with conductive soles or personal grounding
straps.
1. Turn off the air supply to the meter
2. Allow air to exhaust out of the exhaust air port.
3. Turn off the fluid supply to the meter
.
Be sure ventilation fans are operating properly
.
.
Operation
4. Shut off all electrical power to the fluid system or
air system.
Operate the flow meter between 20–50 psi (140–350
kPa, 1.4–3.5 bar) air inlet pressure. The yellow flow
meter indicator light will come on when the proper air
pressure is supplied. The green flow meter indicator
light will blink on and off when the fluid is flowing.
5. Follow the Pressure Relief Procedure for your fluid
system dispensing device.
6
308–287
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Maintenance
Flushing the Meter
CAUTION
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
Do not immerse the meter in solvent. Solvent could
damage the meter s electrical components.
’
1. Clean the fluid and air line filters daily
.
2. Clean the outside of the meter with a soft cloth
dampened in a compatible solvent as needed.
1. Relieve the pressure.
2. Connect the fluid line to the solvent supply unit.
3. Flush the meter until it is clean.
3. Flush the fluid supply line and meter fluid reservoir
daily with a compatible solvent as instructed at
right.
4. Relieve the pressure, then disconnect the fluid
line from the solvent supply unit.
5. Reconnect the fluid line to the fluid (paint) supply
.
6. Turn on the fluid supply
.
7. Operate until the meter and fluid line are free of
solvent.
308–287
7
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Troubleshooting
Before servicing this equipment always make sure to
relieve the pressure
WARNING
.
Installing and servicing this equipment requires
access to parts that may cause electric shock or
other serious injury if the work is not performed
properly. Do not install or service this equipment
unless you are trained and qualified.
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
Problem
ellow LED is off; no power to
flow meter
Cause
Solution
Insufficient air supply
Adjust air regulator.
Y
Turbine alternator not working
Check for dirt or moisture in turbine.
Faulty turbine alternator
Be sure plug is in place on back of
turbine alternator housing. Remove
and test alternator
.
Excess moisture in air lines
Use filter-moisture separator
.
Turbine not connected to PC board
Connect 3-pin connector to square
pins.
T
op PC board not connected to bot
-
Tighten bolts to compress gasket to
tom PC board
0.040” (1.02 mm)
Alternator shorted to chassis
Check that insulating pad (2a) is in
place. Replace pad if necessary
.
Meter gasket (5) is damaged
Replace gasket.
Dried paint/fluid in gear track (gears
are not moving)
Flush fluid section of meter as
instructed in Maintenance on page
7, or disassemble and clean the
Green LED is of
f
gear housing assembly
Replace faulty gears.
Replace meter
.
W
orn gears
Electronic failure
.
8
308–287
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Service
2. Disconnect the 3-pin connector (J) from the square
WARNING
pins (H).
Installing and servicing this equipment requires
access to parts that may cause electric shock or
other serious injury if the work is not performed
properly. Do not install or service this equipment
unless you are trained and qualified.
3. Carefully pull the alternator (4) away from the top
housing.
4. Using an ohmmeter, test the coil in the turbine
alternator. Measure the resistance between the
two outer terminals of the 3-pin connector (J). The
resistance should be 3–5 ohms. If the reading
varies from this value, replace the alternator (4).
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
5. Lubricate the alternator o-ring (4a) seal with petro
-
NOTE: Check all possible remedies in the Trouble-
leum jelly
.
shooting section before disassembling the meter
.
6. Insert the alternator (4) into the top chassis (3).
1. Relieve the pressure and flush the meter as
described on page 7.
7. Connect the 3-pin connector (J) to the 3 square
pins (H) in the top chassis (3).
2. Disconnect the fiber optic cable(s) (G) from the
electronic module (B). See Fig. 3.
8. Check to see that the gasket (5) is not damaged. If
damaged, replace the gasket.
3. Disconnect the air hose fitting and remove the air
hose from the motor. Disconnect both fluid hose
9. Snap the top and bottom chassis together
.
fittings and remove the fluid hose from the meter
.
10. Install and tighten the chassis screws (9) to 40
4. Remove the four screws (A) to separate the gear
housing (F) from the manifold.
in-lbs (4.52 NSm).
KEY
9
H
J
2
3
4
Pins
T
orque to
3
CAUTION
3-pin Connector
Bottom Chassis
40 in-lb
(4.52 NSm)
Never remove the electronic module (B) from the top
gear housing (E). The electronic module is calibrated
to the gear housing assembly and will not function
properly if removed.
Top Chassis
Alternator
4a Alternator O-Ring
5
9
Gasket
Chassis Screws
Torque to 7.5
KEY
ft-lb (10 NSm)
A
B
C
D
E
F
Screw
H
A
4a
4
Electronic Module
O-Ring
Manifold
G
B
F
T
op Gear Housing
Gear Housing Assy
Fiber Optic Cable
.
J
G
5
C*
D
2
E
01851
Fig. 3
Replacing the Turbine Alternator
1. Remove the top chassis (3) from the bottom
chassis (2). See Fig. 4.
0180A
Fig. 4
308–287
9
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Service
3. Install the o-ring (M*), washers (K*), and gear
Replacing Worn Bearings
assemblies (L*). Be sure to install the gears on
their proper pegs. See Fig. 5.
A
repair kit is available to service the bearings. An
asterisk after the description or reference letter indi
cates a part included with the repair kit. See page 1
-
1
4. Press the gear housings together and secure them
with the four screws (N). Torque the screws to 7.5
ft-lbs (10 NSm).
to order the proper kit for your meter model.
CAUTION
This is a close-tolerance device. It will be damaged if
5. Install the meter back onto the adapter plate.
forced apart during disassembly
.
When installing the screws (A), replace the meter’s
two o-rings (C*) with the o-rings from the kit.
1. Loosen the four screws (N). See Fig. 5. Leave
about two threads connected.
Torque screws to 7.5 ft-lbs (10 NSm). See Fig. 3.
NOTE: Kit 223–276 has two sets of o-rings. Use the
o-rings that match the o-rings you are replacing and
discard the others.
2. The two halves of the gear housing are pegged
together and will be difficult to separate. The pegs
are part of the top gear housing (E).
Hold the housing and tap the screws one at a time
in a consistent sequence and eventually the two
halves will come apart.
CAUTION
Never immerse a meter in solvent for cleaning. Doing
3. Before removing the gears (L), note which peg the
gear is being removed from. The gears must be
installed on the same peg they were removed
from.
so will damage the electronics.
KEY
E
K
L
M
N
T
op Gear Housing
CAUTION
Always reinstall the gears on the peg they were
removed from to ensure proper calibration with the
electronic module.
Washer
Gear Assembly
O-Ring
Screw
4. Remove the gears (L) and washers (K).
K*
5. Support a gear on its sides and position the bear
-
ing tool (T*) as shown in Fig. 6. Make sure the
gear has sufficient clearance in the center to press
out the bearings and spacers.
E
L
K*
M*
6. Press the bearing tool with an arbor press or tap it
with a soft hammer until the bearings and spacers
Replace whenever
disassembled
are removed. Repeat with the other gear
.
To install the kit parts and assemble the gear housing:
1. Place a gear on a flat surface. Position the bear
-
ings (P*), spacers (R* and S*) and the bearing tool
(T*) as shown in Fig. 7.
N
1b
Torque to
7.5 ft-lb
(10 NSm)
2. Press the bearing tool with the arbor press or tap it
with a soft hammer until bearings and spacers are
01852A
Fig. 5
installed into the gear. Repeat with the other gear
.
10
308–287
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Service
Removing Bearings
Installing Bearings
KEY
KEY
L
Gear Assembly
L
Gear
T* Bearing Tool
V* Bearings and Spacers
P* Bearing
R* Inner Spacer
S* Outer Spacer
T* Bearing Tool
*T
W
Support
U
Flat Surface
*T
R*
P*
P*
V
*S
L
W
L
U
0968
0969
Fig.
6
Fig. 7
Parts
Bearing Repair Kit 223–276
K
T
P
R
For Meter Model 235–402,
with 0.1 cc per tooth fluid volume flow
S
P
Bearing Repair Kit 223–277
Gears not
included
with Kit
For Meter Model 235–403,
with 0.4 cc per tooth fluid volume flow
Bearing Repair Kits include the following parts:
Ref.
K
Letter Description
Qty.
M
C
K
M
P
R
S
T
O-RINGS, (not shown, See Fig. 3)
WASHER
O-RING
2 or 4
4
1
4
2
2
1
BEARINGS
INNER SPACER
OUTER SPACER
BEARING TOOL
0967
308–287 11
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Parts
Part No. 235–402, Series A
0.1 cc per tooth fluid volume flow
Part No. 235–403
with 0.4 cc per tooth fluid volume flow
16
8
3
30
29
28
17
4a
4
5
Model
235–402 only
9
1
Model
2a
235–403 only
2
1a
1b
6
7
10
11
12
13
14
15
12
308–287
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Parts
Ref
No.
Part No. 235–402, Series A
0.1 cc per tooth fluid volume flow
Part No. Description
Qty.
10
11
12
13
14
15
16*
17*
28
29
30
186–922 FITTING, valve
1
1
1
1
1
1
1
1
2
2
2
Part No. 235–403, Series A
0.4 cc per tooth fluid volume flow
107–107
WASHER, flow
186–921 BODY
101–435 BALL
108–046 SPRING
186–923 RETAINER
187–125 LABEL, warning
187–124 LABEL, warning
111–284 NUT, tube fitting; 1/4” OD
111–285 FERRULE, back; 1/4” OD
111–286 FERRULE, front; 1/4” OD
Ref
No.
Part No. Description
Qty.
1
GEAR HOUSING ASSY; Ordering
information below; Includes
replaceable items 1a & 1b
1
1
2
1a
1b
2
111–073 . O-RING, fluid housing; PTFE
r
111–070 . O-RING, fluid ports; PTFE
224–277 CHASSIS ASSY, bottom;
Includes item 2a
r
*
Additional warning labels available at no charge from
1
1
1
1
1
1
1
1
6
Graco.
2a
3
186–924 . PAD, insulating
224–276 CHASSIS ASSY, top
Vitonr ris aregistered trademark of the Du Pont
4
4a
5
6
7
224–603 ALTERNATOR; Includes item 4a
110–073 . O-RING, alternator; Vitonr
186–852 GASKET, adhesive backing
111–157 FITTING, air inlet; 1/4” tube
186–853 FLAME ARRESTOR
Company.
To Order Gear Housing Assembly (item 1)
To replace the Gear Housing Assembly, you must send
the complete flow meter assembly back to your local
Graco distributor. The flow meter needs to be recali
brated when a new gear housing is installed.
8
9
110–420 SCREW, cap; 10–24 x 1.5”
111–308 SCREW, top mounting;
M4 x 0.7 x 30 mm long
-
2
308–287 13
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Accessories
Fiber Optic Cables
Fluid Manifold
Fiber Optic Cable Assembly
For connection between the controller and flow meter
Contact your local Graco representative to order
proper manifold.
.
PART NO.
LENGTH
224–690
224–691
224–692
224–693
224–694
224–695
224–696
6 ft (1.8 m)
15 ft (5 m)
25 ft (8 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
0186
0187
Part No. 223–869
Part No. 624–708
Fiber Optic Cable Extender
For connection between the flow meter and bulkhead
connector or between two bulkhead connectors.
Fluid Filter 223–160
5000 psi (35.0 MPa, 350 bar) Maximum Working Pressure
P
ART NO.
LENGTH
Stainless steel bowl and polyethylene support.
NOTE: This filter has a 60 mesh screen. To prevent
premature flow meter wear, use a 100 mesh screen.
224–670
224–671
224–672
224–673
224–674
224–675
224–676
6 ft (1.8 m)
15 ft (5 m)
25 ft (8 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
Order Part No. 167–026 when you order the filter
.
100 Mesh Filter Screen 167–026
For use with Fluid Filter 223–160.
Bulkhead Connector 224–261
Bleed-type Master Air Valve 107–142
For connection between two fiber optic cables.
300 psi (2.1 MPa, 21 bar) Maximum Working Pressure
Relieves air trapped in the air line between the pump
air inlet and this valve when closed. 1/2” npt
Grounding Clamp and Wire 222–011
12 ga, 25 ft (7.6 m) wire
14
308–287
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Dimensions
Part No.
235–402
Dim. A
Dim. B
Dim. C
4.25 in
(108 mm)
4.10 in.
(104 mm)
4.44 in.
(113 mm)
DIM. A
235–403
4.25 in
(108 mm)
4.25 in.
(108 mm)
4.50 in.
(114 mm)
DIM. B
DIM. C
01847
Technical Data
Category
Data
Maximum
W
orking Fluid Pressure
2800 psi (19.6 MPa, 196 bar)
50 psi (350 kPa, 3.5 bar)
Maximum Working Air Pressure
Fluid Pressure Operating Range
Air Pressure Operating Range
Air Inlet
0–2800 psi (0–19.6 MPa, 0–196 bar)
20–50 psi (140–350 kPa, 1.4–3.5 bar)
1/4 inch OD tube
Maximum Fiber Optic Cable Length
100 ft (30.5 m) with two splices
Wetted Parts
Stainless Steel, PTFE
r
Manual Change Summary
This manual was revised to include the changes from PCN C.
308–287 15
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The Graco Warranty
Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of
any special extended or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or
replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed,
operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance or structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does 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
transportation.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A
PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT
NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, gas engines,
switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance
in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties
reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures
judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, France, Germany, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 308–287 February 1993, Revised July 1997
16
308–287
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