Graco 313255F, G28C18, G30W82 User Manual

Instructions-Parts

Merkur

Heated

313255F

Spray Packages

For finishing and coating applications requiring heated materials, in hazardous or non-hazardous locations. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 5 for model information, including maximum working pressures and approvals.

ENG

Model G28C18

ti13017a

Model G30W82

ti13016a

ll 2 G c T2

Related Manuals

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Merkur 28:1 Heated Packages

(G28Wxx and G28Cxx) . . . . . . . . . . . . . . . . 6

Merkur 30:1 Heated Packages

(G30Wxx and G30Cxx) . . . . . . . . . . . . . . . . 6

Merkur 48:1 Heated Packages

(G48Wxx) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

General Information . . . . . . . . . . . . . . . . . . . . . . 9

Prepare the Operator . . . . . . . . . . . . . . . . . . . . . 9

Prepare the Site . . . . . . . . . . . . . . . . . . . . . . . . . 9

Wall Mount Packages . . . . . . . . . . . . . . . . . . . . . 9

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 9

Supplied Components . . . . . . . . . . . . . . . . . . . . 10

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Pressure Relief Procedure . . . . . . . . . . . . . . . . 13

Flush Before Using Equipment . . . . . . . . . . . . . 13

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 14

Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 14

Adjust the Atomization . . . . . . . . . . . . . . . . . . . 15

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 15

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Preventive Maintenance Schedule . . . . . . . . . . 17

Tighten Threaded Connections . . . . . . . . . . . . . 17

Flush the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 17

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DataTrak Controls and Indicators . . . . . . . . . . . . . 19

DataTrak Operation . . . . . . . . . . . . . . . . . . . . . . . . 20

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Replace DataTrak Battery or Fuse . . . . . . . . . . 23

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

G28xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 26

G30xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 27

G48Wxx Models . . . . . . . . . . . . . . . . . . . . . . . . 28

Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Wall Mount Kit 24A578 . . . . . . . . . . . . . . . . . . . 29

Heated Cart Mount Kit 256427 . . . . . . . . . . . . . 29

Pump and Gun Control Panel Kit . . . . . . . . . . . 30

Pump Only Control Panel Kit . . . . . . . . . . . . . . . 31

DataTrak Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

PTFE Suction Hose Kits . . . . . . . . . . . . . . . . . . 32

Wall Bracket Mounting Dimensions . . . . . . . . . . . 33

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 34

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 34

Related Manuals

Manual Description

312792 Merkur Displacement Pump 312794 Merkur Pump Assembly 312796

312797 Merkur Spray Packages, Ambient 312798 Merkur Electrostatic Spray

3A0149 AA Series Spray Gun (G15, G40, and

2 313255F

™

NXT

Air Motor

Packages, Ambient and Heated

G40 with RAC)

Manual Description

312145

309524

307273 Fluid Outlet Filter 306860 Back Pressure Regulator 307892 Back Pressure Valve

™

5 and XTR™7 Airless Spray Gun

XTR

Viscon

HP Heater

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.

WARNING

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 unplug 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.

• 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.

313255F 3

Warnings

WARNING

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 manufacturer’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.

• 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 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 in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• 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:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

4 313255F

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.

Wall mount ID

ti12326a

ti12327a

G30 W 80

First Digit

(Merkur

Package)

Second and Third Digits

(Ratio)

28 30 48

28:1 30:1 48:1

Fourth Digit

(Mounting Type)

Cart See Tables, page 6 Wall

Fifth and Sixth Digit

(Components Included)

Cart mount ID

DataTrak™ has the following agency approvals.

#53

Conforms to

FM std 3600 & 3610

for use in Class I Div 1

Group D

T3C Hazardous locations

313255F 5

0359

II 1 G

EEx ia IIA T3

Nemko

06ATEX1124

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)

Model

Wall

Mount G28W07 G28C05 W28EAS 120V XTR G28W08 G28C06 W28EBS 120V XTR G28W09 G28C07 W28EAS 240V XTR G28W10 G28C08 W28EBS 240V XTR G28W17 G28C15 W28EAS 120V G40 G28W18 G28C16 W28EBS 120V G40 G28W19 G28C17 W28EAS 240V G40 G28W20 G28C18 W28EBS 240V G40

Cart

Mount

Pump

Assembly Heater Gun

Air Controls Hoses Options

Pump

Only

✔✔✔ ✔✔

✔✔✔ ✔✔✔

✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔

Gun

and

Fluid

Gun

Hose

✔✔ ✔ ✔ ✔

✔✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔

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)

Model

Wall

Mount G30W67 G30C59 W30CAS 120V XTR G30W68 G30C60 W30CBS 120V XTR G30W69 G30C61 W30CAS 240V XTR G30W70 G30C62 W30CBS 240V XTR G30W79 G30C77 W30CAS 120V G40 G30W80 G30C78 W30CBS 120V G40 G30W81 G30C79 W30CAS 240V G40 G30W82 G30C80 W30CBS 240V G40

Cart

Mount

Pump

Assembly Heater Gun

Air Controls Hose Options

Pump

Only

✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔

✔✔✔ ✔✔

✔✔✔ ✔✔✔

Gun

and

Fluid

Gun

Hose

✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔

✔✔ ✔ ✔ ✔

✔✔ ✔ ✔ ✔ ✔

Gun Fluid Whip Hose

Gun

Air

Hose

Gun

Air

Hose

Siphon

Kit

Siphon

Kit

Fluid Filter DataTrak

Maximum

Fluid Flow

Rate

gpm (lpm)

2.0 (7.5)

Maximum

Fluid Flow

Rate

gpm (lpm)

1.2 (4.5)

6 313255F

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)

Models

Model

Wall

Mount G48W17 ----- W48CAS 120V G48W18 ----- W48CBS 120V

Cart

Mount

Pump

Assembly Heater Gun

Air Controls Hose Options

Gun

Pump

Only

and

Gun

Gun Fluid Hose

Fluid Whip Hose

Gun

Air

Hose

Siphon

Kit

Fluid Filter DataTrak

✔

Maximum

Fluid Flow

Rate

gpm (lpm)

1.2 (4.5)

✔

313255F 7

Installation

ti13112a

ti13007a

FIG. 1: Typical Installation (Your package may not include all items shown.)

Key:

A Air Shutoff Valve (optional

accessory) B Air Filter (optional accessory) C Air Line Moisture Trap and Drain

Valve (optional accessory) D Fluid Heater E Back Pressure Regulator F Fluid Filter G Fluid Drain Valve

8 313255F

HSpray Gun J Gun Swivel K Fluid Whip Hose L Electrically Conductive, Air and

Heated Fluid Supply/Return Hose M 3 Way Valve N Suction Hose and Tube PStrainer R Pump Ground Wire

S Gun Air Pressure Gauge T Gun Air Pressure Regulator U Bleed Type Master Air Valve V DataTrak W Pump Air Pressure Gauge X Pump Air Pressure Regulator Y Insert (for models without

DataTrak)

Installation

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 your system.

FIG. 1 is only a guide for selecting and installing system components and accessories. Contact your Graco distributor 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 thoroughly 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 compressor 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.

Wall Mount Packages

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 operation 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 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 ventilators to prevent gun operation without ventilating fans operating. Check and follow all National, State, and Local codes regarding air exhaust velocity requirements.

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.

313255F 9

Installation

Supplied Components

See FIG. 1. Components vary by package ordered. See tables on pages 6 to 7. Your package may include:

• 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.

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

• The pump air regulator (X) controls pump speed and outlet pressure by adjusting the air pressure to the pump.

• The air relief valve (not shown) opens automatically to prevent overpressurization of the pump.

Do not block access to the valve.

• 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 component rupture. Be sure to keep the heated fluid circulating (turn the 3-way valve to CIRC). Do not install a fluid shutoff device between the heater and the gun.

• The gun air regulator (T) adjusts the air pressure to the air-assisted spray gun (H).

• 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 different spray patterns and rates of flow. Refer to gun manual for tip installation.

• 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.

• The gun swivel (J) allows for freer gun movement.

• The suction hose (N) with strainer (P) allows the pump to draw fluid from a 5 gallon (19 liter) pail.

• A fluid filter (F) with a 60 mesh (250 micron) stainless steel element filters particles from fluid as it leaves the pump.

• DataTrak (V) provides pump diagnostics and material usage information. See page 19.

• The back pressure regulator (E) controls pressure back to the gun and maintains proper circulation pressure.

10 313255F

Installation

Grounding

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 F is attached and tightened securely to the air motor. Connect the other end of the ground wire (R) to a true earth ground.

FIG. 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 recommendations.

IG. 2. Verify that the ground screw (GS)

ti12914a

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 cardboard, which interrupts the grounding continuity.

9. To maintain grounding continuity when flushing or relieving 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 qualified 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 F

IG. 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.

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.

78 (120V only)

ti13261a

IG. 3. Non-Hazardous Location Electrical Cord

313255F 11

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