Graco 312798M User's Manual
Contents
1. 11 Merkur Bellows 23 1 Packages Ambient O2 9BXX sie Sacer put Su dps Hc EO atr Y 11 Merkur 24 1 Packages Ambient G24Wxx and G24Cxx 11 Merkur Bellows 24 1 Packages Ambient G24 B aos qoe Mac od tac d oe Row bed 12 Merkur 28 1 Packages Ambient G28Wxx and G28Cxx 12 Merkur 28 1 Packages Heated G28Wxx and G28Cxx 12 Merkur 30 1 Packages Ambient G30Wxx and G30Cxx 13 Merkur 30 1 Packages Heated G30Wxx and G30Cxx 13 Merkur Bellows 35 1 Packages Ambient O95BD00 ues ce eee ott D eS ux ER 13 Instal ALON ana en Codici a ea cu rodea 3 ia 14 General Information 16 Prepare the Operator LL 16 Prepare the Site 16 Mount the Pump 0000000 16 Ventilate the Spray Booth 17 Components eee eee eee 17 Grounding aa i SR prt aco UE A KA 18 SOLUS ec rM s ats tase Sables Bango Sane tees 19 2 Operations 4624 tie vets see ek eee teks 21 Pressure Relief Procedure 21 Flush Before Using Equipment 21 MOJE DOCK xx tr ob Re an ae UR OR 21 Wet CUP s oboe SE BEN NS Se an 22 Prime the PUImp zis uode oie ee rene 22 Install the Spray Tip 0006 23 Adjust the Atomization 23 Adjust the Spray Pattern 24 Shutdo WD sa ae acd EISE RE EC ERE Dd ard 24 Maintenance2. A witty Min 83b cart mount models 82 ti13018a 36 312798M 312798M ti13114a ti15484b Non Hazardous Location Electrical Cord Parts Cart Mount Only ti13261a ti13260b Parts 37 Parts Heated Models Continued Ref Part Description 1 Varies Pump Assembly see Model tables pages 9 13 and Manual 312794 2 24A581 PANEL air controls i 1 3a 24A576 DATATRAK assembly see manual 1 51364 a INSERT panel included with Part 2 HOSE suction assembly includes Part 1 5 256422 G18xxx and G28xxx Models 256423 G30xxx Models 5 STRAINER suction included with Part 4 239300 FILTER fluid sst see manual 307273 189018 SWIVEL fluid hose 19 1239352 HOSE BUNDLE air and fluid 9a 236130 HOSE air whip 3 ft 0 9 m at y 1 TN Bb GROUND WIRE spraygun 7 16 NUT lock M5 x 0 08 included with Part 2 49 239069 HOSE fluid whip 2 ft 0 6 m 238909 GROUND WIRE pump 49 24E883 AIR CONTROLS MOUNTING KIT wall 1 mount includes 16 and 51 51 SCREW hex head M8 x 16 mm 2 included with Part 49 53 1256427 CART MOUNTING KIT see page 39 1 GxxCxx models only 54 24A578 WALL MOUNTING KIT see page 39 1 GxxWxx models only 24A590 BRACKET heated kit includes 64 65 1 and 66 61 HEATER fluid includes 61a and 61b 1 245848 120V see manual 309524 245863 240V see manual 309524 saj WASHER 4 sm SCREWMBxi2
3. c ccccoccoccocoo 25 Preventive Maintenance Schedule 25 Tighten Threaded Connections 25 Flush the Pump 0c eee ae 25 Wel CUD tea tues yo be BEE EA RAN 25 Troubleshooting c c c 26 DataTrak Controls and Indicators 27 DataTrak Operation 28 SelupiMOGGO 2 39 24 E RD 8 acht SRR AR AE 28 RUN MOGG ois ek ode dA UE end 28 PAIS cout Ear dari ure cer MU ba HAN TOR dea 33 Ambient Models Cart Mount or Wall Mount 33 Bellows Cart Mount 34 Heated Models Cart Mount or Wall Mount 36 Heated Models Continued 38 KIS IRI cr CER 39 Wall Mount Kit 244578 non Bellows 39 Cart Mount Kit 256427 non Bellows 39 Bellows Cart Mount Kit 24E879 40 Bellows Air Control Mounting Kit 40 Pump and Gun Control Panel Kits 41 Air Controls Mounting Kit non Bellows 42 5 Gallon Suction Hose Kits 42 55 Gallon Suction Hose Kits 42 PTFE Suction Hose Kits 42 RICH ne Ann ana an Leni aa Mad Gan SN Rea Bana 42 Drain Valve Kit 256425 42 Overflow Chamber Kit 24E298 42 Mounting Dimensions 43 Wall Bracket Non Bellows 43 Technical Data iius dc mun ha NIC 44 Package Weights 45 AM DEME oui racio aes ane Loan e arses
4. HSSWiD GUN ProXp8S n 1 emn ne pison r TIP OPTION not shown 13 ADAPTER outlet 121237 3 8 nptm x 1 2 nptf used on G18xxx and G28xxx models 121238 3 8 nptm x 3 4 nptf used on G15xxx and G24xxx models 22 239069 HOSE fluid whip 2 ft 0 6 m 37 1166846 ADAPTER for fluid whip hose 1 4 npt x 1 4 npsm 312798M Parts fet Pen Joon Jo 41 1256425 VALVE drain stainless steel includes Parts 44 and 45 Bellows packages only foe hose drain included with E 41 Lm Mull teal e 85 15W719 LABEL warning notshown 7 Non Bellows Mounting Parts 16 NUT lock M5 x 0 08 included with 2 Part 49 24E883 AIR CONTROLS MOUNTING KIT wall includes 16 and 51 51 SCREW hex head M8 x 16 mm included with Part 49 53 256427 CART MOUNTING KIT see page 39 1 GxxCxx models only 54 24A578 WALL MOUNTING KIT see page 39 1 GxxWxx models only Bellows Mounting Parts Ainan sore CTE ao wi PaO 5 30 24EB8O PLATE mounting includes hardware 1 32 fr se LOCKNUT 5mm 55 MOUNTING WEDGE left air control panel cart mount MOUNTING WEDGE right air control panel cart mount S puma 5 104541 LOCKNUTLM8 NUT M8 24E879 ee MOUNTING KIT see Bellows tt Mount Kit page 40 A Replacement Warning labels signs tags and cards are available at no cost 35 Parts Heated Models Cart Mount or Wall Mount Model G30W86 shown 83a wall mount models
5. s ou intentes 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 For patent information see www graco com patents 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 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 Original instructions This manual contains English MM 312798 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2008 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revision M July 2014
6. Ratio Package 15 1 G15C85 112 51 188 63 171 60 112 61 170 60 185 60 114 62 137 62 138 63 28 1 G28C14 115 52 106 48 107 8 ise E lam 15 1 G15W57 85 39 55 G9 56 G9 58 40 55 40 7s G6 55 66 312798M Heated Ratio Package Cart Mount 28 1 G28C19 182 83 28 1 G28C20 183 83 28 1 G28C21 182 83 28 1 G28C22 183 83 30 1 G30C81 173 79 30 1 G30C82 174 79 30 1 G30C83 173 79 30 1 G30C84 174 79 Wall Mount 18 1 G18W13 156 71 18 1 G18W14 157 71 28 1 G28W 1 156 71 28 1 G28W22 157 71 28 1 G28W23 156 71 28 1 G28W24 157 71 30 1 G30W83 147 67 30 1 G30W84 148 67 30 1 G30W85 147 67 30 1 G30W86 148 67 Package Weights 45 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 o
7. or return it to the supply container NOTICE ing efficiency of the electrostatic system Air hose and gun exhaust velocity of 100 ft min 31 linear meters minute should be sufficient e The fluid heater D heats the fluid as it passes through to maintain the correct spraying viscosity Com ponents Read and understand all instructions in the supplied heater manual 309524 before operating the heater See FIG 1 or Fic 2 Components vary by package ordered See tables on pages 9 to 13 Your package Air and Fluid Hoses may include e The red handled bleed type master air valve U is Ambient Models required in your system to relieve air trapped e The red hose AA provides the gun air supply between it and the air motor and gun when the valve is closed Do not block access to the valve e The blue hose Z provides the gun fluid supply e The pump air regulator X controls pump speed Heated Models justing the ai a ewes Sa as e The hose bundle L supplies fluid and air to the gun and allows recirculation of fluid when the gun is e The air relief valve not shown opens automatically not triggered to prevent overpressurization of the pump e The gun air regulator T adjusts the air pressure to the electrostatic air assisted spray gun H e The electrostatic air assisted spray gun H dis penses the fluid The gun houses the spray tip not shown which is available in a wide range of sizes for different s
8. until clear solvent flows from gun 9 Units with runaway protection only disable the prime flush function by pushing the prime flush but ton on the Data Irak 10 Follow Pressure Relief Procedure page 21 11 Clean the tip guard spray tip and fluid filter element separately then reinstall them 12 Clean the inside and outside of the suction tube Wet Cup Fill the wet cup one half full with Graco Throat Seal Lig uid TSL Maintain level daily 25 Troubleshooting Troubleshooting ni 1 uf alt MPa bar Pi pat Fi Relieve the pressure before checking or servicing e Forall problems related to the electrostatics see the equipment Troubleshooting in your gun manual e Check all possible problems and causes before iz 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 8 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 pag
9. which is suitable only for non hazardous location wiring Cart Mount Non Hazardous Location Wiring See FIG 4 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 120 V supplied electrical cord 78 or user supplied cord for 240V applications 312798M Installation ti13261a Fic 4 Cart Mount Non Hazardous Location Wiring Electrical Housing Access Hemove Loosen outer two inner two heater heater bracket bracket screws screws ti13358a Tilt the heater away from the pump for easier access to the screws on the cover of the electrical housing Electrical housing aE ti13359a 19 Installation Heated Hose Connections 1 Attach the right hand thread end of the air hose AA to the gun air regulator T Attach the left hand thread end of the air hose to the air whip hose L Attach the other end of the air whip hose L to the air inlet at base of the gun Attach gun swivel J to the gun fluid inlet Fic 5 Hose Setup 20 Attach one end of the fluid whip hose K to the gun swivel and the other end to the manifold 68 Attach one blue fluid hose to the manifold 68 and to the back pressure regulator 84 Attach the other blue fluid hose to the manifold 68 and to the filter 6 outlet Apply lens cover to both regulator gauge lenses Verify that suction hose
10. 5Bxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 3000 psi 20 7 MPa 207 bar Maximum Pump Hoses _ Options fluid flow and Gun Gun Pump Fluid Gun Fluid Gun Air pese un gpm Ipm Controls Hose Whip Hose Whip Hose DataTrak B35DBO Fluid filter includes fluid drain valve 312798M 13 Installation Installation Package components vary See page 9 to 13 to determine the components included in your model Items designated as accessories are not included in the packages S NS Y X H H J K rg 1 4 d CUS LJ e ti12704b Fic 1 Typical Installation Ambient Model G30C76 Shown n Key A Air Shutoff Valve accessory o Gun Air Pressure Gauge B Air Filter accessory T Gun Air Pressure Regulator C Air Line Moisture Trap and Drain Valve accessory U Bleed type Master Air Valve required F Fluid Filter V Datalrak H Electrostatic Air Assisted Spray Gun W Pump Air Pressure Gauge J Gun Swivel X Pump Air Pressure Regulator K Fluid Whip Hose Y Insert for models without DataTrak see FIG 2 L Air Whip Hose Z Electrically Conductive Gun Fluid Hose N Suction Hose and Tube AA Electrically Conductive Gun Air Hose P Strainer AB Electrostatic Spray Gun Grounding Wire R Pump Grounding Wire A 312798M FiG 2 Typical Installation Heated Model G30W86 Shown Installation ti13167c Key A Air Shutoff Valve accessory N S
11. 5m 4 62 100022 CAPSCREW hex hd 2 uiuo ian ea Isorewmsx25 4 B nmr 4 So w eee II PER INSULATOR heat 68 239864 MANIFOLD recirculating 1 4 npsm 1 38 Description UNION swivel G18xxx and G28xxx Models 15V522 G30xxx Models 70 1113834 BALL VALVE 3 way 1 4 npt m sst DE Sai Gmn taman 1 4 in 6 mm ID 1 4 npsm f 166866 ELBOW 1 4 npt mxf st 2 117627 FITTING couper f UNION swivel 114190 236892 G18xxx and G28xxx Models 75 1239153 HOSE fluid nylon sst fittings 1 2 in 13 1 mm ID 1 2 npt mbe 19 5 in 0 5 15V521 G30xxx Models m long 239108 HOSE fluid recirculation 1 166846 ADAPTER 1 4 18 npsm x 1 4 18 npt 78 115W730 CORD electrical 120V cart mount 1 packages only 79 1112408 STRAIN RELIEF 90 120V cart mount 1 packages only 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 for conduit applications 81 1113934 UNION swivel heater inlet 90 sst 1 2 1 npt fbe 83a 235207 UNION swivel sst 3 8 npt m x 3 8 1 Pr a ON pam wal Mount packages ony ages only manual 306860 eevee A Replacement Warning labels signs tags and cards are available at no cost 312798M Kits Kits Wall Mount Kit 24A578 non Bellows Ref Description Qty 101 SCREW cap M8 x 1 25 4 102 PLATE wall mount 1 NOTE Air Con
12. Air Mount Assembly gpm Ipm Controls Whip Hose Whip Hose Sewu wee 2009 v e ov e ww fe emeeome woes 20081 v e e e v nnt Merkur 28 1 Packages Heated 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 fluid flow and Gun Gun Cart Pump rate Air Fluid Gun Fluid Gun Air Mount Assembly gpm Ipm Controls Whip Hose Whip Hose DataTrak mre nee 2009 as v e v m m rin cana easca nesese 200s fi 240V G28C21 W28EAS 2 0 7 5 6 ap PA v v v v v v 240V G28C22 W28EBS 2 0 75 6 Aue Y v v v v v v v 12 312798M Models Merkur 30 1 Packages Ambient 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 Hoses fluid flow and Gun Gun Cart Pump i Fluid Gun Fluid Gun Air Mount Assembly gpm Ipm Controls Whip Hose Whip Hose DataTrak Merkur 30 1 Packages Heated 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 fluid flow and Gun Gun Cart Pump rate Air Fluid Gun Fluid Gun Air Mount Assembly gpm lpm Controls Hose Whip Hose Whip Hose DataTrak cooler woas 269 elo ee le lel REN CARCER CIN aa eem moe tawa Larang v e y n n le le E Merkur Bellows 35 1 Packages Ambient G3
13. Instructions Parts gt g GRACO Merkur Electrostatic Spray Packages DET For electrostatic finishing and coating applications in hazardous or non hazardous locations including applications that require heated material and applications that use isocyanates UV coatings and other moisture sensitive materials For professional use only Important Safety Instructions e Read all warnings and instructions in this manual Save these instructions See pages 8 to 13 for model information including max imum working pressure and approvals Model G30W86 shown ti13209c CE s PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 WarnitigjS 13 235 599 39 ER EEG EIS eee eee eee 4 Important Two Component Material Information 7 Isocyanate Conditions LL 7 Material Self ignition Ls 7 Keep Components A and B Separate 7 Moisture Sensitivity of Isocyanates 7 Changing Materials lle 7 MOGBIS esc d ac ao des s cR Or a ee ee 8 Agency Approvals llle 9 Merkur 15 1 Packages Ambient G15Wxx and G15Cxx 9 Merkur Bellows 15 1 Packages Ambient NSN do tates cap dh ese te ariaves Gabby mela asian ih 10 Merkur 18 1 Packages Ambient G18Wxx and G18Cxx 10 Merkur 18 1 Packages Heated GOV mna ea cma cc M o Ses 10 Merkur 23 1 Packages Ambient G23Wxx and G23Cxx
14. abels before operating the equipment Prepare the Site Ensure that you have an adequate compressed air supply NOTICE The compressed air supply to the gun must be clean and dry to prevent damage to the finish Use a coalescing air filter in the main air supply line 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 Install a bleed type shutoff valve A in the air line to iso late the air line components for servicing Install an air line filter B and a moisture trap and drain valve C to help remove moisture and contaminants from the com pressed air supply 16 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 Mount the Pump Mount the pump directly to the wall or to a Graco cart See page 39 for mounting kits Wall Mounted Pumps 1 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 operatio
15. ages 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 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
16. als that are compatible with PTFE Includes suction hose swivel and strainer 24B337 3 4 in hose PTFE lined with swivel Cart elbow 24B338 1 in hose PTFE lined with swivel Cart elbow 24B424 3 4 in hose PTFE lined with Wall straight swivel 24B425 1 in hose PTFE lined with straight Wall swivel Data Trak NOTE See DataTrak manual 313541 for all DataTrak related part numbers and kit information including the reed switch and solenoid Drain Valve Kit 256425 Includes drain valve 43 coupling 44 and hose 45 Overflow Chamber Kit 24E298 Merkur Bellows models only See Manual 312793 Includes overflow cup with seals and necessary hard ware 312798M Mounting Dimensions Wall Bracket Non Bellows 11 in 279 mm Mounting Dimensions 4 in 102 mm LH Four 0 40 in 10 mm mounting holes 312798M ti12833a 43 Technical Data Technical Data Merkur Electrostatic Spray Packages Maximum Fluid Working Pressure See Models table on page 8 Maximum Fluid Inlet Pressure 15 psi 0 1 MPa 1 0 bar Bellows Maximum Pump Air Inlet Pressure 100 psi 0 7 MPa 7 0 bar Maximum Gun Air Inlet Pressure 100 psi 0 7 MPa 7 0 bar See Models table on page 8 Ambient Air Temperature Range 35 120 F 2 49 C Sound Data See Technical Data in air motor manual 312796 See manual 312792 Merkur or 312793 Merkur Bellows 44 312798M Package Weights Ambient
17. arking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Keep work area free of debris including solvent rags and gasoline Check gun resistance daily Keep a working fire extinguisher in the work area SPECIAL CONDITIONS FOR SAFE USE Equipment must comply with the following conditions to avoid a hazardous condition which can cause fire or explosion e All label and marking material must be cleaned with a damp cloth or equivalent e The electronic monitoring system is required to be grounded See Grounding instructions ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off air supply before servicing equipment All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Do not touch gun electrode when electrostatics are on Do not expose to rain Store indoors 4 312798M Warnings 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 immed
18. cation 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 G30C76 represents a Merkur package G with a 30 1 ratio pump 30 cart mounting C and the components shown for 76 in the table on page 13 LJ 7 a B YA Wall mount ID D UE a Cart mount ID ti12326a ti12327a Second and Third Digits Fourth Digit Fifth and Sixth Digit Ratio Package Type Components Included o 08580 0 1 0 C Cart Mount See Tables pages 9 13 Package a w stm te Bellows Pump Cart or Wall Mount ala m m 39 3 s 3 8 312798M Models Agency Approvals Merkur Non Heated Electrostatic Packages G15W57 G15W58 G15C85 G15C86 G18W11 G18W12 G18C09 C 2 G c IIA T3 G18C10 G23W13 G23W14 G23C15 G23C16 G24W11 G24W12 G24013 G24C14 G28W15 G28W16 G28C13 G28C14 G30W77 G30W78 G30C75 G30C76 Merkur Heated Electrostatic Packages G18W13 G18W14 G28W21 G28W24 G28C19 G28C22 C Il 2 Gc IIA T2 G30W83 G30W86 G30C81 G30C84M Merkur Bellows Electrostatic Packages G15B83 G15B84 G23B33 G23B34 G24B33 G24B34 G35B33 C Il 2 Gc IIA T3 G35B34 For use in Class I Div I hazardous locations using Group D spray materials APPROVED Pro Xp 85 Manual Electrostatic Air Assisted Spray Gun For use in Group II Zone 1 areas using Group IIA spray materials C Il 2 G EEx 0 24mJ Da
19. correctly e Damaged sensors e Damaged valve carriage Blown Fuse Fuse is blown Replace fuse Faulty solenoid or solenoid see page 31 wiring e Extreme temperatures above 140 F 60 C e Runaway RT FIG 9 protec tion may be enabled with pump that is not equipped with a runaway solenoid valve Enter setup screen and dis able runaway protection 30 312798M DataTrak Operation Replace DataTrak Battery or Fuse 4 Remove two screws on back of module to access A MX battery To reduce the risk of fire and explosion the battery 5 Disconnect the used battery and replace with an and fuse must be replaced in a non hazardous loca approved battery See Table 2 tion Use only an approved replacement battery shown in Table 2 Approved Batteries TABLE 2 and an approved fuse shown in TABLE 3 Energizer alkaline 522 Use of an unapproved battery or fuse will void Varta alkaline 4922 Graco s warranty and Intertek and Ex approvals Ultralife lithium U9V Replace Battery Duracell alkaline MN1604 1 Unscrew cable from the back of the reed switch assembly See FIG 11 2 Remove the cable from the two cable clips ti11992a 3 Remove DataTrak module from bracket See FIG 12 Take module and attached cable to a non haz ardous location ti11884a 312798M 31 DataTrak Operation Replace Fuse Table 3 Approved Fuses 1 Remove the screw metal strap and plastic ho
20. d which interrupts grounding continuity To maintain grounding continuity when flushing or reliev ing pressure always hold a metal part of the spray gun firmly to the side of a grounded metal pail then trigger the gun 312798M Setup Ambient Packages 1 See Fic 1 Attach the blue fluid hose Z to the filter F outlet 2 Attach the right hand thread end of the air hose AA to the gun air regulator T 3 Attach the left hand thread end of the air hose AA to the air whip hose L 4 Attach other end of the air whip hose L to the air inlet at base of gun 5 Attach the gun swivel J to the gun fluid inlet 6 Attach other end of the blue fluid hose Z to the fluid whip hose K 7 Attach other end of the fluid whip hose K to the gun swivel J 8 Apply lens cover to both regulator gauge lenses 9 Verify that suction hose fittings are tight Heated Packages mw 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
21. de press any key to wake up the display then press LH The Prime Flush symbol will appear in the display and 2ib A psi bar m the LED will flash i 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 gt The Prime Flush sym bol will disappear from the display and the LED will stop flashing Counter Totalizer See FIG 9 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 Display See FIG 9 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 Data Irak 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
22. e 28 Bleed extended air from 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 Erratic or accelerated pump Exhausted fluid supply Refill and prime 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 Fluid is visible in the overflow Damaged bellows Replace See manual 312793 chamber 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 26 312798M DataTrak Controls and Indicators DataTrak Controls and Indicators Key for Fic 9 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 T 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 F
23. eben 45 alo eT 45 Graco Standard Warranty 46 Graco Information 46 312798M Related Manuals Related Manuals Manual Description 312792 Merkur Displacement Pump 312793 Merkur Bellows Displacement Pump 312794 Merkur Pump Assembly 312795 Merkur Bellows Pump Assembly 312796 NXT Air Motor 312797 Merkur Non Heated Spray Packages Spray Packages 312798M 3 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 symbols refer to procedure specific risks When these symbols appear in the body of this manual refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear 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 Ground equipment personnel object being sprayed and conductive objects in work area See Grounding instructions Only use grounded Graco conductive air supply hoses Use and clean equipment only in well ventilated area Use cleaning solvents with highest possible flash point when flushing or cleaning equipment Always turn the electrostatics off when flushing cleaning or servicing equipment If there is static sp
24. fittings and drain hose fit tings are tight SS 68 ti13167c 312798M Operation Ww acs Proper electrical grounding of every part of your sys tem is essential Read all Warnings Follow all Grounding instructions See page 18 Check the gun resistance as explained in your separate gun manual Pressure Relief Procedure 1 Engage the trigger lock 2 Turn the gun s ES ON OFF lever to OFF iil ti12582b 3 Close the bleed type master air valve 4 Disengage the trigger lock 5 Hold a metal part of the gun firmly to a grounded metal pail Trigger the gun to relieve pressure 6 Engage the trigger lock 7 Open all fluid drain valves in the system having a waste container ready to catch drainage Leave drain valve s open until you are ready to spray again 8 If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after follow ing the steps above VERY SLOWLY loosen tip 312798M Operation guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Clear hose or tip obstruction 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 Prime the Pump page 22 Trigger Lock Always engage
25. iate surgical treatment Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying 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 Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately 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 Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure 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 inte
26. lder DataTrak Part Fuse Number Required 2 Pullthe fuse away from the board 24C580 289822 3 Replace with an approved fuse from Table 3 mee C and later 24V216 All other part 240580 numbers B and later 24V216 FIG 13 shows where to find the Series letter Solenoid Cable Connection G eocoon 4 e z 0000 Fuse Sensor Cable Connection Series Letter last digit of code ti11994b Fic 13 DataTrak Battery and Fuse Location 32 312798M Parts Parts Ambient Models Cart Mount or Wall Mount Model G30C76 shown ti12637b ti13169a 312798M 33 Parts Bellows Cart Mount 34 ti15429a 312798M Parts pon Joes 1 Varies Pump Assembly see Model tables pages 9 13 and Manual 312794 or 312795 Bellows 2 PANEL air control see page 41 24A581 G15xx to G30xxx models 24A584 G35xxx models 85 psi 3a 24A576 DATATRAK assembly see manual 1 313541 EI INSERT panel included with Part 2 n HOSE suction includes Part 5 G15Cxx G18Cxx G24Cxx G28Cxx G15Bxx G15Wxx G18Wxx G24Bxx G24Wxx G28Wxxx G23Cxx G30Cxx G23Bxx G23Wxx G30Wxx G35Bxx 5 STRAINER included with Part 4 1 6 24A587 FILTER fluid includes Part 7 iw linda A 3 8 18 npt included with Part 6 189018 SWIVEL fludhose fluid hose duda B includes Parts 9a and 9b uM with Part 9 mm GROUND WIRE spray gun included i with Part 9 10
27. lecting an appropriate spray tip for your application Adjust the Atomization MA JD 1 Donotturn on atomizing air supply 2 Turn the gun s ES ON OFF lever to OFF 3 Fluid pressure is controlled by the air pressure sup plied 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 typically 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 exam ple Example Pump Air Approximate Pump Regulator Setting Fluid Pressure Ratio psi MPa bar psig MPa bar 151 x 20 0 14 1 4 300 2 1 21 30 1 x 20 0 14 1 4 600 4 2 42 312798M Operation Hold gun perpendicular and approximately 12 inches 304 mm from surface Move gun first then pull gun trigger to spray onto test paper 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 151 x 7 05 0 5 100 0 7 7 0 30 1 x 3 3 0 02 0 2 100 0 7 7 0 23 Operation Adjust the Spray Pattern 1 See Fic 7 Close off pattern adjustme
28. lush 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 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 ti8622b Setup Mode UT AC i DT nb p t mg F v JataTre system RK PF ti8623b ST Fic 9 DataTrak Controls and Indicators 312798M 2 DataTrak Operation DataTrak Operation NOTE The display AE will turn off after 1 minute to 2 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 3 1 See Fic 9 Press and hold Qo for 5 seconds until Setup menu appears 2 Toenter 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 gt to save the value and move the cur sor to the next data field See page 30 for a descrip tion of E1 E2 and E5 error codes NOTE Graco recommends setting runaway if equipped to 60 a All DataTrak m
29. n and service make sure the pump air inlet fluid inlet and fluid 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 43 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 Cart Mounted Pumps Kit 24E885 is available if you plan to bolt your cart to the floor It includes two spacers that keep the legs stable Bolts not included 312798M Installation Ventilate the Spray Booth 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 Provide fresh air ventilation to avoid the buildup of rial usage information See page 27 flammable or toxic vapors Do not operate the gun unless ventilation fans are operating Supplied with Heated Electrostatic Packages Only 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 The back pressure regulator E controls back pres sure to the gun and maintains proper circulation pressure e The 3 way valve M allows choice to circulate fluid back to the pump
30. nded 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 BI Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDSs 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 chemically impermeable gloves when spraying dispensing or cleaning equipment 312798M 5 Warnings 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 hearing loss inhala tion of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protecti
31. nt air by turn ing knob clockwise in all the way This sets gun for its widest pattern IN wider pattern OUT narrower pattern ti1409b ti1345b Fic 7 Pattern Air Knob 2 See FIG 8 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 too little correct air amount of air Fic 8 Spray Pattern Problems no air TIO792A 24 3 For narrower pattern turn pattern adjustment valve knob counterclockwise out If pattern is still not narrow enough increase air pressure to gun slightly or use different size tip NOTE Follow directions in your gun operation manual supplied to test the electrostatics and to check cover age and wrap on a test piece See Troubleshooting in your gun operation manual if there is a problem Shutdown ZA Vs Follow Pressure Relief Procedure page 21 Always flush the pump before the fluid dries on the dis placement rod See Flush the Pump on page 25 312798M Maintenance Preventive Maintenance Schedule The operating conditions of your particular system determine how often maintenance is required Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed and then determine a regular schedule for checking your
32. odels Merkur 23 1 Packages Ambient G23Wxx and G23Cxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 2300 psi 15 9 MPa 159 bar Options Maximum Pump fluid flow and Gun Gun Cart Pump Fluid Gun Fluid Mount Assembly gpm Ipm Controls Hose Whip Hose Merkur Bellows 23 1 Packages Ambient G23Bxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 2300 psi 15 9 MPa 159 bar Maximum Pump fluid flow and Gun Gun Pump i Fluid Gun Fluid Assembly gpm Ipm Controls Whip Hose Fluid filter includes fluid drain valve Merkur 24 1 Packages Ambient G24Wxx and G24Cxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 2400 psi 16 5 MPa 165 bar Cart Pump i Mount Assembly gpm Ipm Controls 312798M 17 Models Merkur Bellows 24 1 Packages Ambient G24Bxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 2400 psi 16 5 MPa 165 bar Options Maximum Pump fluid flow and Gun Gun Fluid Gun Fluid Assembly gpm Ipm Controls Whip Hose Fluid filter includes fluid drain valve Merkur 28 1 Packages Ambient 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 fluid flow and Gun Gun Cart Pump i Fluid Gun Fluid Gun
33. odules are shipped with runaway protection not enabled NOTE When runaway E1 E2 and E5 error options are enabled a v will appear on the setup screen See FIG 9 3 Move the cursor to the E5 error enable option field then press LH once more to exit Setup mode 4 Run Mode Runaway NOTE Data Irak is available with and without runaway protection Packages with MO2xxx air motors ship with out a runaway solenoid All other packages are eguipped with a runaway solenoid 1 See Fic 9 If pump runaway occurs the runaway solenoid will actuate stopping the pump The LED 5 Runaway Screens 1 and 2 To reset the runaway solenoid close the master air valve U Wait for air to completely bleed off the air motor Runaway Screens 3 and 4 After the air is bled off push the solenoid release button down to reset the air valve The button will pop back up when the air valve is repressurized 4 6 Solenoid release button ti11902a Runaway Screens 5 and 6 Press e to clear the diagnostic code and reset the runaway solenoid Open master air valve U to restart pump AD will flash and the display AE will indicate a NOTE To disable runaway monitoring go to setup runaway condition see Table 1 The display will mode and set runaway value to O zero or toggle RT cycle through six instruction screens off KH see FIG 9 28 312798M Prime Flush 1 See Fic 9 To enter Prime Flush mo
34. on e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 312798M Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocya nates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventila tion in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate per sonal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition W J Some materials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS Keep Components A and B Separate Cross contamination can result in cured material in fluid lines which could cause serious injury or dam age equipment To prevent cross contamination of the equipment s wetted parts never interchange component A isocyanate and component B resin parts 312798M Moisture Sen
35. otection only enable the prime flush function by pushing the prime flush but ton on the Data Irak 9 Open bleed type air valve U Slowly turn clockwise pump air regulator X increasing pressure until pump starts 10 Cycle pump slowly until all air is pushed out and pump and hoses are fully primed 11 Units with runaway protection only disable the prime flush function by pushing the prime flush but ton on the Data Irak 12 Release and lock gun trigger Pump should stall against pressure NOTICE Never allow the pump to run dry of the fluid being pumped A dry pump quickly accelerates to a high speed possibly damaging itself If your pump accel erates quickly or is running too fast stop it immedi ately and check the fluid supply If the supply container is empty and air has been pumped into the lines refill the container and prime the pump and the lines with fluid or flush and leave it filled with a compatible solvent Be sure to eliminate all air from the fluid system 312798M Install the Spray Tip AA Follow Pressure Relief Procedure page 21 Install the spray tip and tip guard as explained in your separate gun manual supplied Be careful not to bend the elec trode wire 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
36. pray patterns and rates of flow Refer to gun manual for tip installation e A gun swivel J allows freer gun movement e The suction hose N with strainer P allows the pump to draw fluid from a 5 gallon 19 liter pail 312798M 17 Installation Grounding When operating the electrostatic gun any ungrounded objects in the spray area people con tainers tools etc can become electrically charged The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electric shock Grounding provides an escape wire for the electric current The following are minimum grounding requirements for a basic electrostatic system Your system may include other equipment or objects which must be grounded Check your local electrical code for detailed grounding instructions Your system must be connected to a true earth ground Pump 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 AC a E SS e ti12914a Fic 3 Ground Screw and Wire Electrostatic Air Assisted Spray Gun Use only the Graco Electrically Conductive Air Supply Hose sup plied Connect the Gun Grounding Wire AC to the ground screw GS on the air motor Heater refer to the heater manual supplied Air compressor follo
37. r 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 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 dam
38. sitivity of Isocyanates Isocyanates ISO are catalysts used in two component coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in vis cosity If used this partially cured ISO will reduce perfor mance and the life of all wetted parts NOTE The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been contam inated from the other side Always lubricate threaded parts with ISO pump oil or grease when reassembling Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing Check with your material manufacturer for chemical compatibility e Most materials use ISO on the A side but some use ISO on the B side Models Models Check the identifi
39. 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 KAS Read all Warnings Follow all Grounding instruc tions See page 18 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 1 Follow Pressure Relief Procedure page 21 2 Besure the ES ON OFF lever is turned to OFF 312798M Maintenance 3 Remove the tip guard and spray tip from gun Refer to separate gun manual 4 Place siphon tube in grounded metal pail containing cleaning fluid 5 Setpump to lowest possible fluid pressure and start pump 6 Hold a metal part of the gun firmly to a grounded metal pail 7 Units with runaway protection only enable the prime flush function by pushing the prime flush but ton on the Data Irak 8 Trigger gun Flush system
40. t m x 1 2T 1 TUBE 1 2 OD cut to fit order Tubing Kit 24D496 ELBOW swivel 1 2T x 3 8 npt m 3 REGULATOR air pump 3 8 npt 1 ELBOW swivel 5 32 T x 1 4 npt 1 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 Kit 24A581 100 psi Kit 24A584 85 psi 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 RING grounding RING grounding 1 NWN NO lt N a s AAA YD S h Kits Air Controls Mounting Kit non Bellows Includes one mounting bracket 49 two lock nuts 16 and two hex head screws 51 Kit Packages 24E883 Air Controls Mounting Kit Wall Mount 5 Gallon Suction Hose Kits Includes suction hose 4 and strainer 5 Wall Cart Cart Both Packages Ambient G23Cxx G30Cxx Ambient G15Cxx G18Cxx G24Cxx G28Cxx Heated G18xxx G28xxx Ambient G23Wxx G30Wxx Wall Ambient Bellows G23Bxx G35Bxx Heated G30xxx Both Ambient G15Wxx G18Wxx Wall G24Wxx G28Wxxx Ambient Bellows G15Bxx G24Bxx 55 Gallon Suction Hose Kits Includes suction hose bung adapter and strainer 24A954 3 4 in hose 24B598 1 in hose 42 PTFE Suction Hose Kits For pumping acid materi
41. taTrak Module p CE Mma Intertek 0359 Ex ia IIA T3 Ga 9902471 ITS13ATEX27862X Class I Div 1 Group D T3A Merkur 15 1 Packages Ambient G15Wxx and G15Cxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 1500 psi 10 3 MPa 103 bar Maximum Pump fluid flow and Gun Gun Cart Pump rate Air Fluid Gun Fluid Gun Air Mount Assembly gpm Ipm Controls Whip Hose Whip Hose DataTrak 312798M 9 Models Merkur Bellows 15 1 Packages Ambient G15Bxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 1500 psi 10 3 MPa 103 bar Options Maximum Pump fluid flow and Gun Gun Fluid Gun Fluid Gun Air Assembly gpm Ipm Controls Whip Hose Whip Hose Fluid filter includes fluid drain valve Merkur 18 1 Packages Ambient G18Wxx and G18Cxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 1800 psi 12 4 MPa 124 bar Maximum Pump fluid flow and Gun Gun Cart Pump i Fluid Gun Fluid Gun Air Mount Assembly gpm Ipm Controls Whip Hose Whip Hose Merkur 18 1 Packages Heated G18Wxx Maximum Inlet Air Pressure 100 psi 0 7 MPa 7 bar Maximum Fluid Working Pressure 1800 psi 12 4 MPa 124 bar Maximum Pump Hoses Options fluid flow and Gun Gun Pump i Fluid Gun Fluid Gun Air Assembly gpm Ipm Controls Whip Hose Whip Hose DataTrak 10 312798M M
42. the trigger lock when you stop spraying to prevent the gun from being triggered accidentally by hand or if dropped or bumped Gun Trigger Locked ti1356a Gun Trigger Unlocked ti1406a 21 Operation Wet Cup AY Before starting fill wet cup 1 3 full with Graco Throat Seal Liquid TSL or compatible solvent ti11927a Fic 6 Fill Wet Cup Prime the Pump NOTICE For pumps with bellows the maximum fluid inlet pres sure is 15 psi 0 1 MPa 1 0 bar Damage to the bel lows may occur if you exceed this pressure Do not use another pump or checking device to supply the bellows pump 1 Turn the gun s ES ON OFF lever to OFF 2 See FIG 1 or FIG 2 Lock gun trigger Remove tip guard and spray tip from gun H Refer to gun man ual 3 Close gun air regulator T and pump air regulator X by turning knobs counterclockwise reducing pressure to zero Close bleed type air valve U Also verify that all drain valves are closed 4 Connect air line to bleed type air valve U 5 Check that all fittings throughout system are tight ened securely 6 Position pail close to pump Suction hose is approxi mately 4 ft 1 2 m long Do not stretch hose tight let it hang to assist fluid flow into pump 22 7 Hold metal part of gun H firmly to side of grounded metal pail unlock trigger and hold trigger open 8 Units with runaway pr
43. trols Mounting Kit 24E883 also is required for wall mounting a package that has a control panel See page 42 ti12633a Cart Mount Kit 256427 non Bellows 202 Ref Part Description Qty 201 CART frame 1 202 HANDLE cart 1 203 119451 WHEEL semi pneumatic 2 204 119452 CAP hub 2 205 SLEEVE cart handle 2 206 15C871 CAP leg 2 207 115480 KNOB t handle 2 208 116630 SCREW carriage 2 209 BRACKET heater cart 1 ti12634a 312798M 39 Kits Bellows Cart Mount Kit 24E879 NA J 15 ii 2 a 58 x 4 17 x 4 ti15580a Ref Description Joy Washer not used 2 i Screw not used 2 1 not 17 Screw MBx16 B 18 Spacers notused 2 80 Plate mounting 58 Locknu 3mm 4 40 Bellows Air Control Mounting Kit Kit 24E884 includes right and left mounting wedges 55 and 56 lock nuts 32 and screws 37 D K In c e F ian es N ti15483a 312798M Kits Pump and Gun Control Panel Kits 304 311 307 308 324 ti13467a ti13565a 321 302 Kit 24A581 and Kit 24A584 Ref 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 324 325 Part 114362 15T643 121212 15T536 15T498 151866 151500 113498 120306 164672 151538 114381 151539 116514 24P814 24P813 312798M Description Qty VALVE ball 1 SWIVEL tee 3 8 np
44. uction Hose and Tube B AirFilter accessory P Strainer C Air Line Moisture Trap and Drain Valve accessory R Pump Grounding Wire D Fluid Heater o Gun Air Pressure Gauge E Back Pressure Regulator T Gun Air Pressure Regulator F Fluid Filter U Bleed Type Master Air Valve required G Fluid Drain Valve V DataTrak H Electrostatic Air Assisted Spray Gun W Pump Air Pressure Gauge J Gun Swivel X Pump Air Pressure Regulator K Fluid Whip Hose Y Insert for models without Data Trak L Air Whip Hose Z Electrically Conductive Heated Fluid Supply Return Hose M 3 Way Valve AA Electrically Conductive Gun Air Hose AB Electrostatic Spray Gun Grounding Wire 312798M 15 Installation General Information NOTE Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing NOTE Always use Genuine Graco Parts and Accesso ries available from your Graco distributor If you supply your own accessories be sure they are adequately sized and pressure rated for your system FiG 1 and FiG 2 are only guides for selecting and installing system components and accessories Contact your Graco distributor for assistance in designing a sys tem 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 l
45. up the display 312798M DataTrak Operation Diagnostics DataTrak can diagnose several problems with the pump When the monitor detects a problem the LED AD FiG 9 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 once to wake up the display and once more to clear the diagnostic code screen 29 DataTrak Operation Table 1 pU Codes EL Pump running faster than set Increased air pressure DataTrak only runaway limit e Increased fluid output e Exhausted fluid supply Diving Up Leak during upstroke Worn piston valve or packings Leak during downstroke Worn intake valve Low Battery Battery voltage too low to stop Low battery Replace battery runaway see page 31 Service Problem with stopping runaway Damaged solenoid Component 1 e Damaged valve carriage units with e Runaway HT FIG 9 protec runaway tion may be enabled with protection only pump that is not equipped with a runaway solenoid valve Enter setup screen and dis able runaway protection Disconnected Solenoid is disconnected Solenoid unplugged Solenoid e Damaged solenoid wires units with Solenoid is not engaging piston Bracket and solenoid not tight runaway cup against air valve housing protection only Service Problem with sensing valve e Sensors unplugged Component 2 movement e Sensors mounted in
46. w manufacturer s recommenda tions All air and fluid lines must be properly grounded Use only grounded hoses with a maximum of 500 feet 150m combined hose length to ensure grounding con tinuity All electric cables must be properly grounded 18 Object being sprayed keep the workpiece hangers clean and grounded at all times Follow local code All electrically conductive objects or devices in the spray area including paint containers wash cans and tools must be properly grounded All persons entering the spray area shoes must have conductive Cut off soles such as leather or finger of personal grounding glove straps must be worn Rubber or plastic soles are not conductive The operator must not wear gloves that insulate the hand from the spray gun The gloves must be con ductive or modified as shown Cut out 3 in 76 mm square from palm of glove 3 The floor of the spray area must be electrically con ductive and grounded Do not cover the floor with card board or any non conductive material that would interrupt grounding continuity Flammable liquids in the spray area must be kept in approved grounded containers Do not store more than the quantity needed for one shift Fluid supply container follow local code All solvent pails follow local code Use only conductive metal pails placed on a grounded surface Do not place the pail on a non conductive surface such as paper or cardboar
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