Graco 313255K User's Manual
Contents
1. Models Merkur 48 1 Heated Packages G48Wxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 4800 psi 33 1 MPa 331 bar Maximum Pump Gun Fluid Fluid Flow Cart Pump Pump and Fluid Whip Rate Mount Assembly Only Gun Hose Hose DataTrak gpm Ipm mew wascas wv Te esws wess zv v 1 2 4 5 313255K Installation Installation ti13007b FIG 1 Typical Installation Your package may not include all items shown Key A Air Shutoff Valve optional H Spray Gun o Gun Air Pressure Gauge accessory J Gun Swivel T Gun Air Pressure Regulator B Air Filter optional accessory K Fluid Whip Hose U Bleed Type Master Air Valve C Air Line Moisture Trap and Drain L Electrically Conductive Air and V DataTrak Valve optional accessory Heated Fluid Supply Return Hose W Pump Air Pressure Gauge D Fluid Heater M 3Way Valve X Pump Air Pressure Regulator E Back Pressure Regulator N Suction Hose and Tube Y Insert for models without F Fluid Filter P Strainer Data Trak G Fluid Drain Valve R Pump Ground Wire 8 313255K General Information Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing Always use Genuine Graco Parts and Accessories available from your Graco distributor If you supply your own accessories be sure they are adequately sized and pressure rated for yo2. X by turning knobs counterclockwise reducing pressure to zero Close bleed type air valve U Also verify that all drain valves are closed 3 Connect air line to bleed type air valve U 4 Check that all fittings throughout system are tight ened securely 5 Position pail close to pump Suction hose is about 4 ft 1 2 m long Do not stretch hose tight let it hang to assist fluid flow into pump 6 Hold metal part of gun H firmly to side of grounded metal pail unlock trigger and hold trigger open 7 Units with runaway protection only enable the prime flush function by pushing the prime flush but ton lt gt on the DataTrak 14 8 Open bleed type air valve U Slowly turn pump air regulator X clockwise increasing pressure until pump starts 9 Cycle pump slowly until all air is pushed out and pump and hoses are fully primed 10 Units with runaway protection only disable the prime flush function by pushing the prime flush but ton lt gt on the DataTrak 11 Release gun trigger and lock trigger safety Pump should stall against pressure Install the Spray Tip Follow Pressure Relief Procedure page 13 Install the spray tip and tip guard as explained in your separate gun manual supplied The fluid output and pattern width depend on the size of the spray tip the fluid viscosity and the fluid pressure Use the Spray Tip Selection Chart in your gun instruc tion manual as a guide for se
3. 8 3 Move the cursor to the E5 error enable option field then press lt gt once more to exit Setup mode Run Mode Runaway NOTE DataTrak is available with and without runaway protection Packages with MO2xxx air motors ship with out a runaway solenoid All other DataTrak packages are equipped with a runaway solenoid 1 See FIG 8 If pump runaway occurs the runaway solenoid will actuate stopping the pump The LED AD will flash and the display AE will indicate a runaway condition see Table 1 The display will cycle through six instruction screens 20 2 Runaway Screens 1 and 2 To reset the runaway solenoid close the master air valve E Wait for air to completely bleed off the air motor T 100 psi bar 3 Runaway Screens 3 and 4 After the air is bled off push the solenoid release button J down to reset the air valve The button will pop back up when the air valve is repressurized 4 6 ti11902a FIG 9 Solenoid Release Button 4 Runaway Screens 5 and 6 Press 0 to clear the diagnostic code and reset the runaway solenoid 5 Open master air valve E to restart pump NOTE To disable runaway monitoring go to setup mode and set runaway value to O zero or toggle RT off see FIG 8 313255K Prime Flush 1 See FIG 8 To enter Prime Flush mode press any key to wake up the display then press lt The Prime Flush symbol will appear in the display and o Leo w
4. G40 gun 16 2 NUT lock M5 x 0 08 included with Part b 49 239069 HOSE fluid whip 2 ft 0 6 m 1 32 COVER gauge not shown 12 per sheet ual see page 30 for package of 5 sheets 49 24E883 AIR CONTROLS MOUNTING KIT wall 1 P AR unt eludes Bands 51 2 SCREW hex head M8 x 16 mm o N No nO O Q O2 CO Ol i O1 N n ciedad 53 1256427 CART MOUNTING KIT see page 29 1 Pt exe medal cnt 54 24A578 WALL MOUNTING KIT see page 29 1 AE enwa moas onm 24A590 BRACKET heated kit includes 64 65 1 Cee peace 61 HEATER fluid 245848 120V see manual 309524 Pope 240V see manual 309524 2 100022 CAPSCREW hex hd 2 econ mi 100527 SCREWM8x25 fe a pu EN A p Ser 167002 SCREW MEx725 fa 4 INSULATOR heat 26 Description MANIFOLD recirculating 1 4 npsm 15V521 UNION swivel 1 113834 BALL VALVE 3 way 1 4 npt m sst 71 239062 HOSE drain nylon sst fittings 1 1 4 in 6 mm ID 1 4 npsm f 166866 ELBOW 1 4 npt m x f sst 75 239153 HOSE fluid nylon sst fittings 1 2 in 13 mm ID 1 2 npt mbe 19 5 in 0 5 m long 76 239108 HOSE fluid recirculation 166846 ADAPTER 1 4 18 npsm x 1 4 18 npt 78 15W730 CORD electrical 120V cart mount 1 iun EMI 79 112408 STRAIN RELIEF 90 120V cart mount 1 An age o 1 BUSHING 107219 For use with supplied cord 120V cart mount packages only 3 4 npt m x 1 2 nptf 185065 Supplied with heater fo
5. pressure hold a metal part of the spray gun firmly to the side of a grounded metal pail then trigger the gun Setup The Viscon HP Heater must be installed by a quali fied electrician in compliance with all state and local codes and regulations Wall Mount Electrical Connections Follow all directions and requirements in the Viscon HP Heater manual 309524 Cart Mount Hazardous Location Wiring The heater is shipped with a fitting that is suitable for wiring in hazardous locations Follow all directions and requirements in the Viscon HP Heater manual 309524 Do not use the supplied electrical cord which is suitable only for non hazardous location wiring Cart Mount Non Hazardous Location Wiring See FIG 3 Replace installed fitting with bushing 80 shipped loose Attach strain relief bushing 79 Follow all directions in the Viscon HP Heater manual 309524 to connect the 120V supplied electrical cord 78 or user supplied cord for 240V applications 78 Y 120V only di Fa a ti13261a FIG 3 Non Hazardous Location Electrical Cord Installation Electrical Housing Access Remove outer two heater8 bracket SCrews Tilt the heater away from the pump for easier access to ti13358a Loosen inner two heater bracket Screws the screws on the cover of the electrical housing 12 ae ti13359a Hose Connections See FIG 1 page 8 1 Attach one end of the a
6. the prime flush but ton lt gt on the DataTrak 7 Trigger gun Flush system until clear solvent flows from gun 8 Units with runaway protection only disable the prime flush function by pushing the prime flush but ton lt gt on the DataTrak 9 Follow Pressure Relief Procedure page 13 10 Clean the tip guard spray tip and fluid filter element separately then reinstall them 11 Clean inside and outside of suction tube Wet Cup Fill the wet cup one half full with Graco Throat Seal Liq uid TSL Maintain level daily Troubleshooting Troubleshooting JE Ny d 3 Relieve the pressure before checking or servicing the equipment NOTE Check all possible problems and causes before LA disassembling the pump Pump fails to operate Restricted line or inadequate air sup Clear line or increase air supply Check that ply closed or clogged valves the valves are open Obstructed fluid hose or gun fluid Open clear use hose with larger ID hose ID is too small Fluid dried on the displacement rod Clean always stop the pump at the bottom of its stroke keep the wet cup 1 3 filled with Graco throat seal liquid TSL Dirty worn or damaged air motor Clean or repair air motor See manual parts 312796 DataTrak models only Air valve can Enable runaway protection See DataTrak not cycle because solenoid pin is Operation Setup Mode page 20 Bleed extended air fro
7. 10 GIOUNGING 2d do D d ber arc n E eA 11 OLD usce ard da resi ditus DE adan 11 Operation usw ax a eee di 13 Pressure Relief Procedure 13 Flush Before Using Equipment 13 is cust oed acd id e ete e OS o arnt 13 TECUM 14 Prime the Pump lesse 14 Install the Spray Tip LLL 14 Adjust the Atomization 15 Adjust the Spray Pattern 15 OBUEQOOWEY s aso iato toot se RR SO E d oe cC 16 Related Manuals Description 312792 Merkur Displacement Pump 312794 Merkur Pump Assembly 312796 NXT Air Motor 312797 Merkur Spray Packages Ambient 312798 Merkur Electrostatic Spray Packages Ambient and Heated 3A0149 AA Series Spray Gun G15 G40 and G40 with RAC Mamtenarnce iia 17 Preventive Maintenance Schedule 17 Tighten Threaded Connections 17 Flush th Pump esce bees ook ES eee ae 17 Wet CUD 2 024 ue Sb oe a C DOOR aac 17 Troubleshooting rn RE mere 18 DataTrak Controls and Indicators 19 DataTrak Operation 20 SCD MOJE y 22 tico ven fa tadas 20 Hl MOOG casco da pda eS ecc ge ed acea 20 Replace DataTrak Battery or Fuse 23 Pais usus iV Was vu dd ie dece di SE 24 32 900 MOE S uius e A ea cede d 26 G30xxx Models lees 27 G48Wxx Models lesen 28 KIS crys See DP XXE pueda eh xd teda 29 Wall Mount Ki
8. 2 502265 BUSHING reducerppe T 84 222200 VALVE back pressure sst dada NN 85 16A619 SPRCER n 2 86 11493 KNOB A unus Not sold separately NOTE Replacement Warning labels signs tags and cards are available at no cost 313255K Kits Wall Mount Kit 24A578 102 101 t112633a Heated Cart Mount Kit 256427 Ref No Part No 201 202 203 119451 204 119452 202 208 215 206 15C871 207 115480 208 116630 210 111799 211 104541 212 115643 213 100022 214 100527 215 167002 203 204 211 213 214 ti13357a 313255K Ref No Description Qty 101 WALL PLATE kit includes screws 1 102 SCREW included with 101 4 Description CART frame HANDLE cart WHEEL semi pneumatic CAP hub SLEEVE cart handle CAP leg KNOB t handle SCREW carriage BRACKET heater cart SCREW cap hex head NUT lock SCREW hex washer head SCREW cap hex head WASHER plain INSULATOR heat Not sold separately Kits NOTE Air Controls Mounting Kit 24E883 Part 49 see page 26 27 or 28 also is required for wall mounting a package that has a control panel 2 lt ANNOAR NHONMNHINN 29 Kits Pump and Gun Control Panel Kit 304 311 307 308 Kit 24A581 Ref 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 30 Part 114362 151643 121212 151536 151498 151866 151500 11349
9. 3255K 3 Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed i
10. 8 164672 151538 114381 151539 116514 105332 15V204 Description Qty VALVE ball 1 SWIVEL tee 3 8 npt m x 1 2T 1 TUBE 1 2 OD cut to fit 1 3 ft order Tubing Kit 24D496 ELBOW swivel 1 2T x 3 8 npt m REGULATOR air pump 3 8 npt ELBOW swivel 5 32 T x 1 4 npt TUBE black cut to fit order Tubing Kit 24D496 SWIVEL 90 5 32T x 1 8 npt f ELBOW swivel 5 32T x 1 8 npt GAUGE pressure VALVE safety ADAPTER NUT regulator SCREW cap button head REGULATOR air gun 3 8 npt NUT regulator PANEL LABEL panel not shown INSERT NUT lock not shown ELBOW 1 2T x 1 2 npt COVER lens 12 sticker sheet not shown order Kit 24A540 for 5 sheets O2 iN gt NY gt WO po py t113565a 313255K Kits Pump Only Control Panel Kit Kit 24A583 Ref 301 303 304 305 306 307 308 310 311 313 314 317 318 319 320 321 322 326 Part 114362 121212 151536 151498 151500 113498 151538 114381 313255K Description VALVE ball TUBE 1 2 OD cut to fit order Tubing Kit 24D496 ELBOW swivel 1 2T x 3 8 npt m REGULATOR air 3 8 npt ELBOW swivel 5 32 T x 1 4 npt TUBE black cut to fit order Tubing Kit 24D496 SWIVEL 90 5 32T x 1 8 npt f GAUGE pressure VALVE safety NUT regulator SCREW cap button head PANEL LABEL panel not shown INSERT see inset illustration on page 30 NUT lock not shown ELBO
11. Clear the tip orifice b The gun fluid filter or the fluid hose may be com pletely clogged Very slowly loosen the hose end coupling at the gun and relieve pressure gradually Then loosen completely to clear the obstruction c After following the steps above if the spray tip or hose still seems completely clogged very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually then loosen completely With tip removed trig ger gun into waste container 313255K Operation Flush Before Using Equipment The equipment was tested with lightweight oil which is left in the fluid passages to protect parts To avoid con taminating your fluid with oil flush the equipment with a compatible solvent before using the equipment See Flush the Pump page 17 Trigger Lock See FIG 4 Always engage gun trigger lock when you stop spraying to prevent gun from being triggered acci dentally by hand or if dropped or bumped Gun Trigger p Safety Locked 2P Tl6581A Gun Trigger Safety Unlocked p d TI6582A Fic 4 Trigger Lock 13 Operation Wet Cup ZA i Before starting fill wet cup 1 3 full with Graco Throat Seal Liquid TSL or compatible solvent ti11927a FIG 5 Wet Cup Prime the Pump 1 See FIG 1 Lock gun trigger Remove tip guard and spray tip from gun H Refer to gun manual 2 Close gun air regulator T and pump air regulator
12. IPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All wri
13. Instructions Parts gt y GRACO Merkur Heated Spray Packages ime For finishing and coating applications requiring heated materials in hazardous or non hazardous locations For professional use only Australian Patent No 2006275866 Important Safety Instructions e Read all warnings and instructions in this manual Chinese Patent Nos ZL200680027833 0 and Save these instructions ZL200680027760 5 European Community Patent No 1910678 Russian Patent No 2413096 Ukrainian Patent Nos 59881 89254 and 93051 United States Patent No 8 066 491 Other patents pending See pages 5 to 7 for model information including maxi mum working pressures and approvals Model Model G28C18 G30W82 ti13017a ti3016b C C Eicon C HOO03 PROVEN QUALITY LEADING TECHNOLOGY Related Manuals Contents Related Manuals 2 WarninOS 33 52 352599 3 Perea eee eee 3 NMOJBIS iurc eo Nae b xoa aea d e 5 Merkur 28 1 Heated Packages G28Wxx and G28Cxx 6 Merkur 30 1 Heated Packages G30Wxx and G30Cxx 6 Merkur 48 1 Heated Packages GO VV IO id edad bos td deo UR ed dob 7 INSTA Mas detras Stade ae APR ae CN 8 General Information 9 Prepare the Operator 9 Prepare the Site llus 9 Wall Mount Packages 9 Ventilate the Spray Booth 9 Supplied Components 0005
14. W 1 2T x 1 2 npt see inset illustration on page 30 307 308 304 t113567a Qty 1 5 ft a N al NN dol N COVER lens 12 sticker sheet not 1 shown order Kit 24A540 for 5 sheets FITTING straight 1 2T x 3 8 npt m 1 31 Kits Data Trak NOTE See DataTrak manual 313541 for all Data Trak related part numbers and kit information including the reed switch and solenoid 32 PTFE Suction Hose Kits For pumping acid materials that are compatible with PTFE Includes suction hose swivel and strainer Kit Description Wall Cart 24B424 3 4 in hose PTFE lined with Wall straight swivel 24B425 1 in hose PTFE lined with straight Wall swivel 313255K Wall Bracket Mounting Dimensions Wall Bracket Mounting Dimensions 11 in 279 mm Four 0 40 in 10 mm ti12833a mounting holes Technical Data Maximum fluid working pressure See Models table on page 5 Maximum pump air inlet pressure 100 psi 0 7 MPa 7 0 bar Maximum gun working pressure 100 psi 0 7 MPa 7 0 bar A A ea hee M See Models table on page 5 Ambient air temperature range 35 F 120 F 2 C 49 C Maximum fluid temperature 160 F 71 C SOULd data air ds ahh ee ae See Technical Data in air motor manual 312796 Welted Balls uo aco ps UE nd SEEDS Eee ERES Displacement pump Stainless steel tungst
15. e schedule by recording when and what kind of maintenance is needed and then determine a regular schedule for checking your system Replace lens covers on regulator gauge lenses when dirt makes gauges difficult to read Tighten Threaded Connections Before each use check all hoses for wear or damage Replace as necessary Check that all threaded connec tions are tight and leak free Flush the Pump Ww Read all Warnings Follow all Grounding instruc tions See page 11 Flush the pump e Before first use e When changing colors or fluids e Before repairing equipment e Before fluid dries or settles out in a dormant pump check the pot life of catalyzed fluids e At the end of the day e Before storing the pump Flush at the lowest pressure possible Flush with a fluid that is compatible with the fluid you are pumping and with the wetted parts in your system Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency 313255K Maintenance 1 Follow Pressure Relief Procedure page 13 2 Remove tip guard and spray tip from gun Refer to separate gun manual 3 Place siphon tube in grounded metal pail containing cleaning fluid 4 Setpump to lowest possible fluid pressure and start pump 5 Hold a metal part of the gun firmly to a grounded metal pail 6 Units with runaway protection only enable the prime flush function by pushing
16. en carbide with 6 nickel UHMWPE PTFE Spray gun See Manual 3A0149 AA guns or Manual 312145 XTR gun Fluid hoses nylon Suction assembly stainless steel nylon Fluid filter See Manual 307273 Heater Stainless steel Back pressure regulator See Manual 306860 Back pressure valve See Manual 307892 Drain valve stainless steel nylon 313255K 33 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale 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
17. enoid wires e Bracket and solenoid not tight against air valve housing e Sensors unplugged e Sensors mounted incorrectly e Damaged sensors e Damaged valve carriage e Faulty solenoid or solenoid wir ing e Extreme temperatures above 140 F 60 C e Runaway RT FIG 8 protection may be enabled with pump that is not equipped with a runaway solenoid valve Enter setup screen and disable runaway pro tection 313255K DataTrak Operation Replace DataTrak Battery or Fuse 4 Remove two screws on back of module to access A WM battery The battery and fuse must be replaced in a 5 Disconnect the used battery and replace with an non hazardous location approved battery See FIG 12 Use only the following approved replacement batter ies Use of an unapproved battery will void Graco s Replace Fuse warranty and FM and Ex approvals 1 Remove the screw metal strap and plastic holder e Ultralife lithium U9VL e Duracell alkaline MN1604 2 Pull the fuse away from the board e Energizer alkaline 522 e Varta alkaline 4922 3 Replace with a new fuse Use only a Graco approved replacement fuse Order Part 24C580 Solenoid Cable Connection Replace Battery 1 Unscrew cable from the back of the reed switch assembly See FIG 10 2 Remove the cable from the two cable clips Sensor Cable Connection ti11992a Fic 10 Disconnect DataTrak 3 Re
18. ge 29 M duelli iai d 24A578 WALL MOUNTING KIT see page 29 il o NM 24A590 BRACKET heated kit includes 64 65 udi MM 61 HEATER fluid 245848 120V see manual 309524 Pope 240V see manual 309524 ni 100022 CAPSCREW hex hd ddr 63 100527 WASHER 1 4 in 1 4 in epe SOREWM x25 e LO LIMEN A poe SCREW Mes ee 313255K Parts ai 67002 INSULATOR heat EN 68 239864 MANIFOLD recirculating 1 4 npsm mE 113834 BALL VALVE 3 way 1 4 npt m 239062 HOSE drain nylon sst a 166866 ELBOW 1 4 npt m x f sst 117627 FITTING coupler 75 239153 HOSE fluid nylon sst fittings 1 2 in 13 1 mm ID 1 2 npt mbe 19 5 in 0 5 m long 239108 HOSE fluid recirculation NN AE 15W730 CORD electrical 120V cart mount packages gs 79 112408 STRAIN RELIEF 90 120V cart mount packages only 113934 UNION swivel heater inlet 90 sst 1 2 npt fbe i 502265 BUSHING reducer pipe reducer BUSHING reducer pipe 83b 207123 UNION swivel 90 cart mount packages 1 only 84 238926 REGULATOR back pressure sst see 1 manual 306860 Description 69 15V522 UNION swivel EE 1 4 in 6 mm ID 1 4 npsm f 236892 UNION swivel 77 166846 ADAPTER 1 4 18 npsm x 1 4 18 npt E BUSHING 107219 For use with supplied cord 120V cart mount packages only 3 4 npt m x 1 2 nptf 185065 Supplied with heater for conduit applications 83a 235207 UNION swivel sst 3 8 npt m x 3 8 npsm f wall mount packa
19. ges only Not sold separately NOTE Replacement Warning labels signs tags and cards are available at no cost 27 Parts G48Wxx Models NPN pesen PUMP ASSEMBLY W48CAS M18LNO x LWO75A W48CBS M18LTO x LWO75A e PANEL air controls pump and gun PIU P oos do 42 ard 43 soe pago 90 3a 24A576 DATATRAK assembly see manual 313541 E 3b INSERT panel included with Part 2 16 un E M5 x 0 08 included with Part 2 EVER gauge not shown 12 per sheet see page 30 for package of 5 EE 48 238909 GROUND WIRE pump GROUND WIRE pump 24E883 AIR CONTROLS MOUNTING KIT wall ad SCREW hex head M8 x 16 mm included T with Part 49 54 24A578 WALL MOUNTING KIT see page 29 1 24A590 BRACKET heated kit includes 64 65 1 and 66 LU 245848 HEATER fluid 120V see manual 309524 ae Hs CAPSCREW hex hd 1 4 20 x 1 25 in 31 mm 28 Description G3 00827 WASHER Md 2 CIC Le amp Nu EN x SCREW M8 x 1 25 4 87187002 INSULATOR heat UNION swivel 70 113834 BALL VALVE 3 way 1 4 nptim sst dad c oo ND 1 4 i in 6 mm ID 1 4 npsm f 72 166866 ELBOW 1 4 npt A SSt em 236892 UNION swivel RT LE 24C406 HOSE fluid nylon sst fittings 1 2 in 13 mm ID 1 2 14 nps m 3 ft 0 9 m long 239108 HOSE fluid recirculation za 77 112494 ADAPTER 3 8 18 nps m x 1 4 18 mpt 1 114874 UNION swivel heater inlet 90 sst didus 7 2 8
20. h the pump When the monitor detects a problem the LED AD FIG 8 will flash and a diagnostic code will appear on the dis play See Table 1 To acknowledge the diagnosis and return to the normal operating screen press e once to wake up the display and once more to clear the diagnostic code screen 21 DataTrak Operation Table 1 Diagnostic Codes e Increased air pressure e Increased fluid output e Exhausted fluid supply Pump running faster than set runaway limit Runaway DataTrak only 16 26 x m m C x cy J 3 6 oL 18 LO a Diving Up Leak during upstroke Diving Down Leak during downstroke Low Battery Battery voltage too low to stop runaway Service Component Problem with 1 stopping runaway units with runaway protection only Disconnected Solenoid units with runaway protection only Solenoid is not engaging piston cup 112 Service Component Problem with 2 sensing valve movement Fuse is blown Replace fuse see page 23 Blown Fuse 22 Worn piston valve or packings Worn intake valve Low battery Replace battery see page 23 e Damaged solenoid e Damaged valve carriage e Runaway RT FIG 8 protection may be enabled with pump that is not equipped with a runaway solenoid valve Enter setup screen and disable runaway pro tection Solenoid is e Solenoid unplugged disconnected e Damaged sol
21. improper design manufacture installation operation or maintenance of 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 THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE 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 EQU
22. ir hose to the gun air regula tor T G40 spray guns only Attach the other end of the air hose to the air inlet at the base of the gun G40 spray guns only Attach gun swivel J to the gun fluid inlet Attach one end of the fluid whip hose K to the gun swivel and the other end to the recirculating mani fold Attach one blue fluid hose to the recirculating mani fold and to the back pressure regulator E Attach the other blue fluid hose to the recirculating manifold and to the filter F outlet Apply lens cover to both regulator gauge lenses Verify that suction hose fittings and drain hose fit tings are tight 313255K Operation Pressure Relief Procedure MA O vi 1 Engage the trigger lock 2 See FIG 1 Turn off the bleed type master air valve U 3 Disengage the trigger lock 4 Hold a metal part of the gun firmly to a grounded metal waste container Trigger the gun to relieve fluid pressure 5 Engage the trigger lock 6 Open all fluid drain valves in the system having a waste container ready to catch the drainage Leave the drain valve s open until you are ready to spray again 7 If you suspect that pressure has not been fully relieved after following the steps above check the following a The spray tip may be completely clogged Very slowly loosen the air cap retaining ring to relieve pressure in the cavity between the ball seat shutoff and the plugged tip
23. ir ts OIOIOIOIZITIO the LED will flash a T o OT min 2 While in Prime Flush mode runaway protection is disabled and the batch totalizer BT will not count The grand totalizer GT continues to count 3 Toexit Prime Flush mode press any key to wake up the display then press lt The Prime Flush sym bol will disappear from the display and the LED will stop flashing Counter Totalizer See FIG 8 The last digit of the batch totalizer BT rep resents tenths of gallons or liters To reset the totalizer press any key to wake up the display then press and hold e for 3 seconds e If AC is set to gallons or ounces BT and GT dis play gallons e If AC is set to liters or cc BT and GT display liters e If AC is set to cycles BT and GT display cycles Press e to toggle between flow rate units and cycles A letter under the BT display indicates that both BT and GT are displaying gallons g or liters I No letter means both BT and GT are displaying cycles 313255K DataTrak Operation Display See FIG 8 The display AE will turn off after 1 minute of inactivity in Run mode or 3 minutes in Setup mode Press any key to wake up the display NOTE DataTrak will continue to count cycles when dis play is off NOTE The display AE may turn off if a high level static discharge is applied to the DataTrak Press any key to wake up the display Diagnostics DataTrak can diagnose several problems wit
24. lator T adjusts the air pressure to the air assisted spray gun H e The air assisted or airless spray gun H dispenses the fluid The gun houses the spray tip not shown which is available in a wide range of sizes for differ ent spray patterns and rates of flow Refer to gun manual for tip installation e The hose bundle L supplies fluid and air for AA guns to the gun and allows recirculation of fluid when the gun is not triggered e The gun swivel J allows for freer gun movement e The suction hose N with strainer P allows the pump to draw fluid from a 5 gallon 19 liter pail e A fluid filter F with a 60 mesh 250 micron stain less steel element filters particles from fluid as it leaves the pump e DataTrak V provides pump diagnostics and mate rial usage information See page 19 e The back pressure regulator E controls pressure back to the gun and maintains proper circulation pressure 10 The 3 way valve M allows choice to circulate fluid back to the pump or return it to the supply container A fluid drain valve G relieves fluid pressure in the hose and gun The fluid heater D heats the fluid as it passes through to maintain the correct spraying viscosity Read and understand all instructions in the supplied heater manual 309524 before operating the heater Heat causes fluid to expand If the heated fluid is trapped with nowhere to expand it can cause compo nent rupture Be
25. lecting an appropriate spray tip for your application 313255K Adjust the Atomization ZA 1 Do not turn on atomizing air supply Fluid pressure is controlled by the air pressure supplied to the pump pump air regulator Set fluid pressure at low starting pressure For low viscosity fluids less than 25 sec 2 Zahn cup with lower percent solids typi cally less than 40 start at 300 psi 2 1 MPa 21 bar at pump outlet For fluids with higher viscosity or higher solids content start at 600 psi 4 2 MPa 42 bar Refer to the following example Example Pump Air Approximate Pump Regulator Setting Fluid Pressure Ratio psi MPa bar psig MPa bar 15 1 x 20 0 14 1 4 300 2 1 21 30 1 x 20 0 14 1 4 600 4 2 42 2 Hold gun perpendicular and approximately 12 inches 304 mm from surface 3 Move gun first then pull gun trigger to spray onto test paper 4 Increase fluid pressure in 100 psi 0 7 MPa 7 bar increments just to the point where a further increase in fluid pressure does not significantly improve fluid atomization Refer to the following example Example Pump Air Regulator Incremental Pump Increment Fluid Pressure Ratio psi MPa bar psi MPa bar 15 11 x 7 05 0 5 100 0 7 7 0 301 x 3 3 0 02 0 2 100 0 7 7 0 313255K Operation Adjust the Spray Pattern Packages with Airless Guns The spray tip orifice and spray angle determine pattern coverage and
26. luid outlet ports are easily accessible 3 Using the wall bracket as a template drill 0 4 in 10 mm mounting holes in the wall Wall mounting dimensions are shown on page 33 4 Attach the bracket to the wall Use 3 8 in 9 mm screws that are long enough to keep the pump from vibrating during operation NOTE Be sure the bracket is level Ventilate the Spray Booth Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors Do not operate the gun unless ventilation fans are operating Electrically interlock the gun air supply with the ventila tors to prevent gun operation without ventilating fans operating Check and follow all National State and Local codes regarding air exhaust velocity require ments Installation Supplied Components See FIG 1 Components vary by package ordered See tables on pages 6 to 7 Your package may include e The red handled bleed type master air valve U is required in your system to relieve air trapped between it and the air motor and gun when the valve is closed Do not block access to the valve Trapped air can cause the pump to cycle unexpect edly which could result in serious injury from splash ing or moving parts e The pump air regulator X controls pump speed and outlet pressure by adjusting the air pressure to the pump e The air relief valve not shown opens automatically to prevent overpressurization of the pump e The gun air regu
27. m motor Press e on the DataTrak display to retract solenoid pin Pump operates but output is Restricted line or inadequate air sup low on both strokes ply closed or clogged valves the valves are open hose ID is too small pump low on downstroke or piston packings 312794 speed Held open or worn ball check valves Clear valve replace packings see manual or packings 312794 Fluid being pumped is visible Worn throat packings Replace throat packings See manual in the TSL reservoir 312794 To determine if the fluid hose or gun is obstructed relieve the pressure Disconnect the fluid hose and place a con tainer at the pump fluid outlet to catch any fluid Turn on the air just enough to start the pump It the pump starts when the air is turned on the obstruction is in the hose or gun 18 313255K DataTrak Controls and Indicators DataTrak Controls and Indicators Key for FIG 8 AA AB AC AD AE PF AE see details at right Runaway Limit in cycles per minute user settable 00 OFF Lower Displacement user settable Flow Rate Units user settable to min gpm US gom Imperial oz min US oz min Imperial l min or cc min LED fault indicator when lit Display Prime Flush Key Enables Prime Flush mode While in Prime Flush mode runaway protection is disabled and the batch totalizer BT will not count LED will flash while in Prime Flush mode ti11883a Fic 8 DataTrak Control
28. move DataTrak module from bracket See FIG 11 Take module and attached cable to a non haz Battery ardous location ti11994a FIG 12 DataTrak Battery and Fuse Location ti11884a 313255K 23 Parts Parts NOTE Parts vary by model See Parts Lists on pages 26 to 28 3b G48xxx G28xxx and G30xxx Models if r 83a wallmount models 83b cart mount models ti13018a Ol A 69 70 71 24 313255K Parts Non Hazardous Location Electrical Cord Parts 120V Cart Mount Only 78 120V ma ti13261a t15484b G40 Gun Shown i M 2 gt i 22 68 ti13114a 9 ti13143a 313255K 25 Parts G28xxx Models No parto Description 1 PUMP ASSEMBLY M18LNO x LW125A M18LTO x LW125A PANEL air controls Pump only see page 31 ly 1 W28EAS 1 Pump and gun see page 30 1 1 1 1 1 W28EBS 24A583 24A581 24A576 DATATRAK assembly see manual 313541 INSERT panel included with Part 2 1 256422 HOSE suction assembly includes Par 5 i t STRAINER suction included with Part 4 FILTER fluid sst see manual 307273 SWIVEL fluid hose packages with AA gun HOSE BUNDLE Packages with XTR gun Packages with G40 gun GUN T M XTR5 G40 3 3b 4 5 39300 89018 bh XTR501 1 di m 6 239300 1 AAMA13 GUN TIP not shown packages with G40 1 gun 12 AAMxxx TIP OPTION not shown packages with 1
29. n the eyes or on skin inhaled or swallowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear impervious gloves when spraying or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 4 313255K Models Models Check the identification plate ID for the 6 digit part number of your package Use the following matrix and tables to define the components of your package For example package number G30W80 represents a Merkur package G with a 30 1 ratio pump 30 wall mounting W and the components shown for 80 in the table on page 6 Cart mount ID 13 a mount X A ab ti12326a ti12327a Second and Third Digits Fourth Digit Fifth and Sixth Digit Ratio Mounting Type Components Included Merkur DataTrak has the following agency approvals M gt CE Ema APPROVED poe EEx ia IIA T3 Conforms to Nemko FM std 3600 amp 3610 O6ATEX1124 for use in Class Div 1 G
30. r conduit applications 81 113934 UNION swivel heater inlet 90 sst 1 2 1 npt fbe 5 BUSHING reducer pipes BUSHING reducer pipe aa UNION swivel sst 3 8 npt m x 3 8 npsm f wall mount packages only only manual 306860 Not sold separately NOTE Replacement Warning labels signs tags and cards are available at no cost 313255K G30xxx Models No Pato Desorption lon 1 PUMP ASSEMBLY 1 W30CAS M12LNO x LWO75A W30CBS M12LTO x LWO75A 2 PANEL air controls includes 3b 42 and 1 43 24A583 Pump only see page 31 24A581 Pump and gun see page 30 24A576 DATATRAK assembly see manual 313541 E 3b NSEHT panel included with Part 2 rr m suction assembly includes Part in nn ns SR Vind suction included with Part4 1 5 E55806 239300 FILTER fluid sst see manual 307273 FILTER Tuis set ses ooa T FI SWIVEL fluid hose packages with AA M gun HOSE BUNDLE 239342 Packages with XTR gun 239311 nC SES with G40 gun XTR501 E 5 24C855 G40 pope GUN TIP not shown packages with 5 rit m m paasee w 990 AAMxxx TIP OPTION not shown packages with ipe renes e E M5 x 0 08 included with Part HE 22 239069 HOSE ORTI 0 6 m 32 COVER gauge not shown 12 per ds see page 30 for package of 5 sheets 238909 GROUNDWIRE pump 24E883 AIR CONTROLS MOUNTING KIT wall lal a mM SCREW hex head M8 x 16 mm included with Part 49 256427 CART MOUNTING KIT see pa
31. roup D T3C Hazardous locations 313255K 5 Models Merkur 28 1 Heated Packages G28Wxx and G28Cxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 2800 psi 19 3 MPa 193 bar Maximum Pump Gun Fluid Fluid Flow Cart Pump Pump and Fluid Whip Rate Mount Assembly Only Gun Hose Hose DataTrak gpm Ipm mmewwemos wses 1204 xR v viv Te Je Gamwosomco webs vv xn v v v v v v Gamwsemow weseas mw xR v v v viv c2swio azacns wesess 2600 xR v v v viv vis mewwemew weseas 12v 60 v v v v jo c2swie azacte wesss 12v Go v v v v v v maeww emerm weseas ww 60 v v v v v Gwajemci wsess mw oo v v e v v Merkur 30 1 Heated Packages G30Wxx and G30Cxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 3000 psi 20 7 MPa 207 bar Maximum Pump Gun Fluid Fluid Flow Cart Pump Pump and Fluid Whip Rate Mount Assembly Only Gun Hose Hose DataTrak gpm Ipm Gxwerawes waocas ww xm v v v v v esowes esocso wsooss ww xm v v v v v v v Y v Y ssowss asocs1 waocas cov xm v v v e ero jesow70 as0c82 waoces zov xm wv v v v s exwm ewcm waocas ww co v v v v v esowso as0c7s waoces ww cao v v v v v v Gxws awcm waocas cov oo v v v v iv Gxwsjewcm wecss mw cao v v e 6 313255K
32. s and Indicators 313255K HK Reset Key Resets faults Press and hold for 3 seconds to clear the batch totalizer Push to toggle between flow rate and cycle rate With runaway protection enabled push to extend and retract the solenoid pin Cycle Flow Rate Batch Totalizer Grand Totalizer Runaway Toggle enable disable E1 Toggle E2 Toggle E5 Toggle Run Mode FE 0 0 0 0 2 1 0 DataTrak ti8622b Setup Mode UT DT m Y Ja alre ECTRONIC MONIZO ING SYSTEM Y PF ti8623b ST 19 DataTrak Operation DataTrak Operation NOTE The display AE will turn off after 1 minute to save battery life Press any key to wake up the display NOTICE To prevent damage to the softkey buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails Setup Mode 1 See FIG 8 Press and hold for 5 seconds until Setup menu appears 2 To enter settings for runaway if equipped lower size and flow rate units and to enable runaway E1 E2 and E5 error options press e to change the value then lt gt to save the value and move the cur sor to the next data field See page 22 for a descrip tion of E1 E2 and E5 error codes NOTE Graco recommends setting runaway if equipped to 60 T All DataTrak modules are shipped with runaway protection not enabled NOTE When runaway E1 E2 and E5 error options are enabled a Y will appear on the setup screen See FIG
33. size When you need more coverage use a larger spray tip rather than increasing fluid pressure Align guard horizontally to spray a horizontal pattern Align guard vertically to spray a vertical pattern Packages with AA Guns 1 See FIG 6 Close off pattern adjustment air by turn ing knob AA clockwise in all the way This sets gun for its widest pattern AA m y IN wider Se 7X pattern AA OUT narrower pattern i 3 A TI6559A Fic 6 Pattern Air Knob 2 See FIG 7 Set atomizing air pressure at about 5 psi 0 35 bar 35 kPa when triggered Check spray pat tern then slowly increase air pressure until tails are completely atomized and pulled into spray pattern Do not exceed 100 psi 0 7 MPa 7 bar air pressure to gun Operation 3 See FIG 7 For narrower pattern turn pattern adjustment valve knob AA counterclockwise out If pattern is still not narrow enough increase air pressure to gun slightly or use different size tip no air too little air correct amount of HO792A air Fic 7 Spray Pattern Problems Shutdown BAS vi Follow Pressure Relief Procedure page 13 Always flush the pump before the fluid dries on the dis placement rod See Flush the Pump on page 17 16 313255K Maintenance Preventive Maintenance Schedule The operating conditions of your particular system determine how often maintenance is required Establish a preventive maintenanc
34. sure to keep the heated fluid circulat ing turn the 3 way valve to CIRC Do not install a fluid shutoff device between the heater and the gun 313255K Grounding Mulia The equipment must be grounded Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit 1 Pump See FIG 2 Verify that the ground screw GS is attached and tightened securely to the air motor Connect the other end of the ground wire R to a true earth ground Fic 2 Ground screw and wire 2 Pump fluid hoses use only electrically conductive fluid hoses Check electrical resistance of hoses If total resistance to ground exceeds 25 megohms replace hose immediately 3 Viscon HP Heater refer to the heater manual supplied 4 Air compressor follow manufacturer s recommen dations 5 Spray gun ground through connection to a properly grounded fluid hose and pump 6 Fluid supply container follow your local code 7 Object being sprayed follow your local code 313255K Installation 8 Solvent pails used when flushing follow your local code Use only metal pails which are conductive placed on a grounded surface Do not place the pail on a nonconductive surface such as paper or card board which interrupts the grounding continuity 9 To maintain grounding continuity when flushing or relieving
35. t 244578 29 Heated Cart Mount Kit 256427 29 Pump and Gun Control Panel Kit 30 Pump Only Control Panel Kit 31 Data lla xut doe thx urea res Dx edd e 32 PTFE Suction Hose Kits 32 Wall Bracket Mounting Dimensions 33 Technical Dalai n o re caca s 33 Graco Standard Warranty 34 Graco Information 34 Manual Description 312145 XTR 5 and XTR 7 Airless Spray Gun 309524 Viscon HP Heater 307273 Fluid Outlet Filter 306860 Back Pressure Regulator 307892 Back Pressure Valve 313255K Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unpl
36. tten 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 Original instructions This manual contains English MM 313255 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2009 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised 01 2012
37. ug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment e Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment 31
38. ur system FIG 1 is only a guide for selecting and installing system components and accessories Contact your Graco dis tributor for assistance in designing a system to suit your particular needs Prepare the Operator All persons who operate the equipment must be trained in the operation of all system Components as well as the proper handling of all fluids All operators must thor oughly read all instruction manuals tags and labels before operating the equipment Prepare the Site Ensure that you have an adequate compressed air supply Bring a compressed air supply line from the air com pressor to the pump location Refer to the performance charts in your pump assembly manual to find the air consumption of your pump Be sure all air hoses are properly sized and pressure rated for your system Use only electrically conductive hoses The air hose should have a 3 8 npt m thread A quick disconnect coupling is recommended Keep the site clear of any obstacles or debris that could interfere with the operator s movement Have a grounded metal pail available for use when flushing the system 313255K Installation Wall Mount Packages Be sure the wall can support the weight of the pump bracket hoses and accessories as well as the stress caused during operation 2 Position the wall bracket about 4 5 ft 1 2 1 5 m above the floor For ease of operation and service make sure the pump air inlet fluid inlet and f
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