Graco 313255N, Merkur Heated Spray Packages Instructions

Instructions-Parts

Merkur

®

Heated

Spray Packages

313255N

EN

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 pages 5 to 7 for model information, including maxi-

mum working pressures and approvals.

Model

G28C18

Model

G30W82

ti13017a ti13016b

ll 2 G c T2

2

Related Manuals

Contents

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

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

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

Merkur 28:1 Heated Packages

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


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


(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

Related Manuals

Manual 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)

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

G28xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 27

G30xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 28

G48Wxx Models . . . . . . . . . . . . . . . . . . . . . . . . 29

Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Wall Mount Kit 24A578 . . . . . . . . . . . . . . . . . . . 30

Heated Cart Mount Kit 256427 . . . . . . . . . . . . . 30

Pump and Gun Control Panel Kit . . . . . . . . . . . 31

Pump Only Control Panel Kit . . . . . . . . . . . . . . . 32

DataTrak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

PTFE Suction Hose Kits . . . . . . . . . . . . . . . . . . 33

Wall Bracket Mounting Dimensions . . . . . . . . . . . 34

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36

Manual Description

312145

309524

XTR

™

5 and XTR

™

7 Airless Spray Gun

Viscon

®

HP Heater

307273 Fluid Outlet Filter

306860 Back Pressure Regulator

307892 Back Pressure Valve

313255N

Warnings

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.

SPECIAL CONDITIONS FOR SAFE USE

Equipment must comply with the following conditions to avoid a hazardous condition which can cause fire or explosion.

• All label and marking material must be cleaned with a damp cloth (or equivalent).

•

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 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.

313255N 3

4

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

313255N

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.

Wall mount

ID

Cart mount

ID ti12326a ti12327a

G

First Digit

G

(Merkur

Package)

30

Second and Third Digits

(Ratio)

28

30

48

28:1

30:1

48:1

W

C

W

Fourth Digit

(Mounting Type)

Cart

Wall

DataTrak

™

has the following agency approvals.

80

Fifth and Sixth Digit

(Components Included)

See Tables, page 6

9902471

Class I, Div. 1,

Group D T3A

0359

II 1 G

Ex ia IIA T3 Ga

ITS13ATEX27862X

313255N 5

6

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

Cart

Mount

Pump

Assembly Heater

G28W07 G28C05 W28EAS 120V

G28W08 G28C06 W28EBS 120V

G28W09 G28C07 W28EAS 240V

G28W10 G28C08 W28EBS 240V

G28W17 G28C15 W28EAS 120V

G28W18 G28C16 W28EBS 120V

G28W19 G28C17 W28EAS 240V

G28W20 G28C18 W28EBS 240V

Gun

XTR

XTR

XTR

XTR

G40

G40

G40

G40

Air Controls Hoses Options

Pump

Only

Pump and

Gun

Gun

Gun

Fluid

Fluid Whip

Hose Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

2.0 (7.5)


(G30Wxx and G30Cxx)



Model

Wall

Mount

Cart

Mount

Pump

Assembly Heater

G30W67 G30C59 W30CAS 120V

G30W68 G30C60 W30CBS 120V

G30W69 G30C61 W30CAS 240V

G30W70 G30C62 W30CBS 240V

G30W79 G30C77 W30CAS 120V

G30W80 G30C78 W30CBS 120V

G30W81 G30C79 W30CAS 240V

G30W82 G30C80 W30CBS 240V

Gun

XTR

XTR

XTR

XTR

G40

G40

G40

G40

Air Controls Hose Options

Pump

Only

Pump and

Gun

Gun

Gun

Fluid

Fluid Whip

Hose Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter DataTrak

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

Maximum

Fluid Flow

Rate gpm (lpm)

1.2 (4.5)

313255N

Models


(G48Wxx)



Model

Wall

Mount

Cart

Mount

G48W17 -----

0

G48W18 -----

Pump

Assembly Heater

W48CAS 120V

W48CBS 120V

Gun

Air Controls Hose Options

Pump

Only

Pump and

Gun

Gun

Gun

Fluid Gun

Fluid

Hose

Whip

Hose

Air

Hose

✔

✔

Siphon

Kit

Fluid

Filter DataTrak

✔

Maximum

Fluid Flow

Rate gpm (lpm)

1.2 (4.5)

313255N 7

V

S

T

U

Installation

Installation

W ti13112a

X

Y

R

B

C

A

D E

F

G

P

N M

L ti13007b

F

IG

. 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

H Spray 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

P Strainer

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)

8 313255N

H

J

K

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.

F

IG

. 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.

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 34.

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.

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.

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.

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.

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.

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.

313255N 9

Installation

Supplied Components

See F

IG

. 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.

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.

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.

• 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 mate-

rial usage information. See page 19.

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

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.

10 313255N

Installation

Grounding

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.

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.

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

IG

. 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.

Setup

The Viscon HP Heater must be installed by a qualified electrician in compliance with all state and local codes and regulations.

F

IG

GS

. 2. Ground screw and wire

ti12914a

R

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.

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.

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.

80

79

78

(120V only) ti13261a

F

IG

. 3. Non-Hazardous Location Electrical Cord

313255N 11

Installation

Electrical Housing Access

Remove outer two heater bracket screws (8).

Loosen inner two heater bracket screws.

ti13358a

Tilt the heater away from the pump for easier access to the screws on the cover of the electrical housing.

Electrical housing

Hose Connections

See F

IG

. 1, page 8.

1.

Attach one end of the air hose to the gun air regulator (T, G40 spray guns only).

2.

Attach the other end of the air hose to the air inlet at the base of the gun (G40 spray guns only).

3.

Attach gun swivel (J) to the gun fluid inlet.

4.

Attach one end of the fluid whip hose (K) to the gun swivel and the other end to the recirculating manifold.

5.

Attach one blue fluid hose to the recirculating manifold and to the back pressure regulator (E).

6.

Attach the other blue fluid hose to the recirculating manifold and to the filter (F) outlet.

7.

Apply lens cover to both regulator gauge lenses.

8.

Verify that suction hose fittings and drain hose fittings are tight.

ti13359a

12 313255N

Operation

Operation

Pressure Relief Procedure Flush Before Using Equipment

The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment. See

Flush the Pump, page 17.

1.

Engage the trigger lock.

2.

See F

IG

. 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. Clear the tip orifice.

b.

The gun fluid filter or the fluid hose may be completely 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, trigger gun into waste container.

Trigger Lock

See F

IG

. 4. Always engage gun trigger lock when you stop spraying to prevent gun from being triggered accidentally by hand or if dropped or bumped.

Gun Trigger

Safety Locked

Gun Trigger

Safety Unlocked

F

IG

. 4. Trigger Lock

TI6581A

TI6582A

313255N 13

Operation

Wet Cup

Before starting, fill wet cup 1/3 full with Graco Throat

Seal Liquid (TSL) or compatible solvent.

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 button on the DataTrak.

11. Release gun trigger and lock trigger safety. Pump should stall against pressure.

Install the Spray Tip

Wet

Cup

F

IG

. 5. Wet Cup

ti11927a

Prime the Pump

1.

See F

IG

. 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

(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 tightened 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 button on the DataTrak.

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 instruction manual as a guide for selecting an appropriate spray tip for your application.

14 313255N

Operation

Adjust the Atomization Adjust the Spray Pattern

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 (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 example.

Example:

Pump

Ratio

15:1 x

30:1 x

Pump Air

Regulator Setting psi (MPa, bar)

20 (0.14, 1.4)

20 (0.14, 1.4)

Approximate

Fluid Pressure psig (MPa, bar)

= 300 (2.1, 21)

= 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

Ratio

15:1 x

30:1 x

Pump Air Regulator

Increment psi (MPa, bar)

7 (.05, 0.5)

3.3 (0.02, 0.2)

Incremental

Fluid Pressure psi (MPa, bar)

= 100 (0.7, 7.0)

= 100 (0.7, 7.0)

Packages with Airless Guns

The spray tip orifice and spray angle determine pattern coverage and 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 F

IG

. 6. Close off pattern adjustment air by turning knob (AA) clockwise (in) all the way. This sets gun for its widest pattern.

OUT (narrower pattern)

AA

F

IG

. 6. Pattern Air Knob

AA

IN (wider pattern)

TI6559A

2.

See F

IG

. 7. Set atomizing air pressure at about 5 psi

(0.35 bar, 35 kPa) when triggered. Check spray pattern, 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.

313255N 15

Operation

3.

See F

IG

. 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 air

F

IG

. 7. Spray Pattern Problems

Shutdown

ti0792A

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 313255N

Maintenance

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 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 connections are tight and leak-free.

Flush the Pump

Read all Warnings. Follow all Grounding instruc-

tions. See page 11.

Flush the pump:

• Before first use

• When changing colors or fluids

• Before repairing equipment

• Before fluid dries or settles out in a dormant pump

(check the pot life of catalyzed fluids)

• At the end of the day

• 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.


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.

Set pump 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 the prime/flush button 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 button on the DataTrak.

9.


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 Liquid (TSL). Maintain level daily.

313255N 17

Troubleshooting

Troubleshooting

NOTE: Check all possible problems and causes before disassembling the pump.

F

Relieve the pressure before checking or servicing the equipment.

Problem

Pump fails to operate.

Pump operates, but output is low on both strokes.

Pump operates, but output is low on downstroke.

Erratic or accelerated pump speed.

Fluid being pumped is visible in the TSL reservoir.

Cause Solution

Restricted line or inadequate air supply; closed or clogged valves.

Obstructed fluid hose or gun; fluid hose ID is too small.

Clear line or increase air supply. Check that the valves are open.

Open, clear*; use hose with larger ID.

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 parts.

Clean or repair air motor. See manual

312796.

DataTrak models only: Air valve cannot cycle because solenoid pin is extended

Enable runaway protection (See DataTrak

Operation, Setup Mode, page 20). Bleed

air from motor. Press on the DataTrak display to retract solenoid pin.

Clear line or increase air supply. Check that the valves are open.

Restricted line or inadequate air supply; closed or clogged valves.

Obstructed fluid hose or gun; fluid hose ID is too small.

Worn packings in displacement pump.

Open, clear*; use hose with larger ID.

Replace packings. See manual 312794.

Held open or worn ball check valves or piston packings.

Exhausted fluid supply.

Held open or worn ball check valves or packings.

Worn throat packings.

Clear valve; replace packings. See manual

312794.

Refill and prime.

Clear valve, replace packings; see manual

312794.

Replace throat packings. See manual

312794.

* To determine if the fluid hose or gun is obstructed, relieve the pressure. Disconnect the fluid hose and place a container 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 313255N

DataTrak Controls and Indicators

DataTrak Controls and Indicators

Key for F

IG

. 8

AA Runaway Limit, in cycles per minute (user settable;

00=OFF)

AB Lower Displacement (user settable)

AC Flow Rate Units (user settable to

/min,

gpm [US], gpm

[Imperial], oz/min [US], oz/min [Imperial], l/min, or cc/min)

AD LED (fault indicator when lit)

AE Display

PF 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.

RK 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.

CF Cycle/Flow Rate

BT Batch Totalizer

GT Grand Totalizer

RT Runaway Toggle (enable/disable)

UT E1 Toggle

DT E2 Toggle

ST E5 Toggle

GT

AE, see details at right

Run Mode

RK PF

AD ti11883a

AC

AB

RK

AA

CF

Setup Mode

BT ti8622b

RT

UT

DT

PF

ST ti8623b

F

IG

. 8. DataTrak Controls and Indicators

313255N 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.

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.

Setup Mode

1.

See F

IG

. 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 to change the value, then 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 . All DataTrak modules are shipped with runaway protection not enabled.

NOTE: When runaway, E1, E2, and E5 error options are enabled, a

✓

will appear on the setup screen.

See F

IG

. 8.

3.

Move the cursor to the E5 error enable option field, then press once more to exit Setup mode.

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.

F

IG

. 9. Solenoid Release Button

ti11902a

J

Run Mode

4.

Runaway Screens 5 and 6: Press to clear the diagnostic code and reset the runaway solenoid.

Runaway

NOTE: DataTrak is available with and without runaway protection. Packages with M02xxx air motors ship without a runaway solenoid. All other DataTrak packages are equipped with a runaway solenoid.

1.

See F

IG

. 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.

5.

Open master air valve (E) to restart pump.

NOTE: To disable runaway monitoring, go to setup mode and set runaway value to 0 (zero) or toggle (RT) off (see . 8).

20 313255N


Prime/Flush

1.

See F

IG

. 8. To enter Prime/Flush mode, press any key to wake up the display, then press . The

Prime/Flush symbol will appear in the display and the LED will flash .

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.

To exit Prime/Flush mode, press any key to wake up the display, then press . The Prime/Flush symbol will disappear from the display and the LED will stop flashing.

Counter/Totalizer

See F

IG

. 8. The last digit of the batch totalizer (BT) represents tenths of gallons or liters. To reset the totalizer, press any key to wake up the display, then press and hold for 3 seconds.

• If AC is set to gallons or ounces, BT and GT display gallons.

• If AC is set to liters or cc, BT and GT display liters.

• If AC is set to cycles, BT and GT display cycles.

Display

See F

IG

. 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 display 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 with the pump.

When the monitor detects a problem, the LED (AD, F

IG

.

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 once to wake up the display, and once more to clear the diagnostic code screen.

Press 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 (l). No letter means both BT and GT are displaying cycles.

313255N 21


Symbol

Table 1:Diagnostic Codes

Runaway

(DataTrak only)

Diagnosis Cause

Pump running faster than set runaway limit.

• Increased air pressure.

• Increased fluid output.

• Exhausted fluid supply.

22

E-1

E-2 Diving Down

E-3

Diving Up

Low Battery

Leak during upstroke.

Worn piston valve or packings.

Leak during downstroke.

Worn intake valve.

Battery voltage too low to stop runaway.

Low battery. Replace battery; see

page 23.

E-4

E-4

E-5

E-6

Service Component

1

(units with runaway protection only)

Problem with stopping runaway.

Disconnected

Solenoid

(units with runaway protection only)

Solenoid is disconnected.

Solenoid is not engaging piston cup

(112).

Service Component

2

Problem with sensing valve movement.

• Damaged solenoid.

• Damaged valve carriage.

• Runaway (RT, F

IG

. 8) protection may be enabled with pump that is not equipped with a runaway solenoid valve. Enter setup screen and disable runaway protection.

• Solenoid unplugged.

• Damaged solenoid wires.

• Bracket and solenoid not tight against air valve housing.

• Sensors unplugged.

• Sensors mounted incorrectly.

• Damaged sensors.

• Damaged valve carriage.

Blown Fuse Fuse is blown.

Replace fuse; see

page 23.

• Faulty solenoid or solenoid wiring.

• Extreme temperatures (above

140°F [60°C]).

• Runaway (RT, F

IG

. 8) protection may be enabled with pump that is not equipped with a runaway solenoid valve. Enter setup screen and disable runaway protection.

313255N


Replace DataTrak Battery or Fuse

To reduce the risk of fire and explosion, the battery and fuse must be replaced in a non-hazardous location.

Use only an approved replacement battery, shown in

T

ABLE

2, and an approved fuse, shown in T

ABLE

3.

Use of an unapproved battery or fuse will void

Graco’s warranty and Intertek and Ex approvals.

Replace Battery

1.

Unscrew cable from the back of the reed switch assembly. See F

IG

. 10.

2.

Remove the cable from the two cable clips.

4.

Remove two screws on back of module to access battery.

5.

Disconnect the used battery and replace with an approved battery. See Table 2.

Table 2. Approved Batteries

Energizer alkaline # 522

Varta alkaline # 4922

Ultralife lithium # U9V

Duracell alkaline # MN1604 ti11992a

F

IG

. 10. Disconnect DataTrak

3.

Remove DataTrak module from bracket. See F

IG

.

11. Take module and attached cable to a non-hazardous location.

F

IG

. 11. Remove DataTrak

ti11884a

313255N 23


Replace Fuse

1.

Remove the screw, metal strap, and plastic holder.

2.

Pull the fuse away from the board.

3.

Replace with an approved fuse from T

ABLE

3.

Table 3. Approved Fuses

DataTrak Part

Number

289822

All other part numbers

Series*

A or B

C and later

A

B and later

Fuse

Required

24C580

24V216

24C580

24V216

* F

IG

. 12 shows where to find the Series letter.

Solenoid Cable

Connection

Fuse

Sensor Cable

Connection

Series Letter

(last digit of code)

Battery

F

IG

. 12. DataTrak Battery and Fuse Location

ti11994b

24 313255N

Parts

Parts

NOTE: Parts vary by model. See Parts Lists on pages 27 to 29.

3a

5

313255N

3b

2

1

4

48

64

62

63

67

66

67

74

73 81

76

77

85

84

86

G48xxx

Models

G28xxx and

G30xxx

Models

6

83a

(wall mount models)

83b

(cart mount models)

77

76

60

64

72

76

75

61 82 ti13018a

69 70 71

25

Parts

60

53

16

49

51 ti13114a

16

65 t15484b

Non-Hazardous Location Electrical

Cord Parts (120V Cart Mount Only)

80

79

78 (120V only) ti13261a

G40 Gun

Shown

10

8

22

68

9 ti13143a

26 313255N

Parts

G28xxx Models

Ref.

No. Part No. Description Qty.

1

W28EAS

W28EBS

PUMP ASSEMBLY

M18LN0 x LW125A

M18LT0 x LW125A

2

24A583

24A581

PANEL, air controls

Pump only, see page 32

Pump and gun, see page 31

3a 24A576 DATATRAK, assembly, see manual

313541.

3b ----INSERT, panel (included with Part 2)

4 256422 HOSE, suction, assembly (includes Part

5)

1

1

1

5 ----STRAINER, suction (included with Part 4) 1

6 239300 FILTER, fluid, sst, see manual 307273 1

1 8 189018 SWIVEL, fluid hose (packages with AA gun)

9

239342

239311

HOSE BUNDLE

Packages with XTR gun

Packages with G40 gun

1

1 10

XTR501

24C855

GUN

XTR 5

G40

11 AAM413 GUN TIP (not shown, packages with G40 gun)

12 AAMxxx TIP OPTION (not shown, packages with

G40 gun)

16 ----NUT, lock, M5 x 0.08 (included with Part

49)

22 239069 HOSE, fluid, whip, 2 ft (0.6 m)

32 ----COVER, gauge, not shown, 12 per sheet

(see page 31 for package of 5

sheets)

1

1

2

1

1

48 238909 GROUND WIRE, pump

49 24E883 AIR CONTROLS MOUNTING KIT, wall mount, (includes 16 and 51)

51 ----SCREW, hex head, M8 x 16 mm

(included with Part 49)

53 256427

CART MOUNTING KIT, see page 30

(GxxCxx models only)

54 24A578

WALL MOUNTING KIT, see page 30

(GxxWxx models only)

1

1

2

1

1

1

1

1 60 24A590 BRACKET, heated, kit, includes 64, 65, and 66)

61

245848

245863

HEATER, fluid

120V, see manual 309524


62 100022 CAPSCREW, hex hd,

1/4-20 x 3/4 in. (19mm)

63 100527 WASHER, 1/4 in.

64 ----SCREW, M8 x 25

65 -----

66 -----

NUT

SCREW, M8 x 1.25

67 167002 INSULATOR, heat

1

2

4

4

2

8

4

Ref.

No. Part No. Description

68 239864 MANIFOLD, recirculating, 1/4 npsm

69 15V521 UNION, swivel

70 113834 BALL VALVE, 3 way, 1/4 npt(m), sst

71 239062 HOSE, drain, nylon, sst fittings,

1/4 in. (6 mm) ID; 1/4 npsm(f)

72 166866 ELBOW, 1/4 npt (m x f), sst

73 117627 FITTING, coupler

74 114190 UNION, swivel

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

77 166846 ADAPTER, 1/4-18 npsm x 1/4-18 npt

78 15W730 CORD, electrical (120V cart mount packages only)

79 112408 STRAIN RELIEF, 90° (120V cart mount packages only)

80

107219

185065

BUSHING

For use with supplied cord (120V cart mount packages only),

3/4 npt(m) x 1/2 nptf

Supplied with heater for conduit applications

81 113934 UNION, swivel, heater inlet, 90°, sst, 1/2 npt(fbe)

82 502265 BUSHING, reducer, pipe

83a 235207 UNION, swivel, sst, 3/8 npt(m) x 3/8 npsm(f), wall mount packages only

83b 207123 UNION, swivel, 90°, cart mount packages only

84 238926 REGULATOR, back pressure, sst, see

manual 306860

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

3

1

----- Not sold separately.

NOTE: Replacement Warning labels, signs, tags, and cards are available at no cost.

313255N 27

Parts

G30xxx Models

Ref.


1

2

W30CAS

W30CBS

24A583

24A581

PUMP ASSEMBLY

M12LNO x LW075A

M12LT0 x LW075A

PANEL, air controls (includes 3b, 42, and

43)

Pump only, see page 32

Pump and gun, see page 31

10

XTR501

24C855

GUN

XTR 5

G40

11 AAM413 GUN TIP (not shown, packages with G40 gun)

1

1

3a 24A576 DATATRAK, assembly, see manual

313541

3b ----INSERT, panel (included with Part 2)

1

4 256423 HOSE, suction, assembly (includes Part

5)

5 ----STRAINER, suction (included with Part 4) 1

6 239300 FILTER, fluid, sst, see manual 307273 1

1 8 189018 SWIVEL, fluid hose (packages with AA gun)

9

239342

239311

HOSE BUNDLE

Packages with XTR gun

Packages with G40 gun

1

1

1

1

1

1 12 AAMxxx TIP OPTION (not shown, packages with

G40 gun)

16 ----NUT, lock, M5 x 0.08 (included with Part

49)

22 239069 HOSE, fluid, whip, 2 ft (0.6 m)

32 ----COVER, gauge, not shown, 12 per sheet

(see page 31 for package of 5

sheets)

48 238909 GROUND WIRE, pump


51 ----SCREW, hex head, M8 x 16 mm

(included with Part 49)

53 256427

CART MOUNTING KIT, see page 30

(GxxCxx models only)

54 24A578

WALL MOUNTING KIT, see page 30

(GxxWxx models only)

60 24A590 BRACKET, heated, kit, includes 64, 65, and 66)

61

245848

245863

HEATER, fluid




1/4-20 x 3/4 in. (19mm)

63 100527 WASHER, 1/4 in.

64 ----SCREW, M8 x 25

65 -----

66 -----

NUT

SCREW, M8 x 1.25

2

2

1

1

1

1

2

1

1

1

1

4

4

2

8

Ref.



68 239864 MANIFOLD, recirculating, 1/4 npsm




1/4 in. (6 mm) ID; 1/4 npsm(f)

72 166866 ELBOW, 1/4 npt (m x f), sst

73 117627 FITTING, coupler


75 239153 HOSE, fluid, nylon, sst fittings; 1/2 in (13 mm) ID, 1/2 npt (mbe), 19.5 in. (0.5 m) long


77 166846 ADAPTER, 1/4-18 npsm x 1/4-18 npt

78 15W730 CORD, electrical (120V cart mount packages only)

79 112408 STRAIN RELIEF, 90° (120V cart mount packages only)

80

107219

185065

BUSHING

For use with supplied cord (120V cart mount packages only),

3/4 npt(m) x 1/2 nptf

Supplied with heater for conduit applications

81 113934 UNION, swivel, heater inlet, 90°, sst, 1/2 npt(fbe)


83a 235207 UNION, swivel, sst, 3/8 npt(m) x 3/8 npsm(f), wall mount packages only

83b 207123 UNION, swivel, 90°, cart mount packages only

84 238926 REGULATOR, back pressure, sst, see

manual 306860

Qty.

1

1

4

1

1

1

1

1

1

1

1

1

1

1

2

1

1

3

1



28 313255N

Parts

G48Wxx Models

Ref.


1

W48CAS

W48CBS

PUMP ASSEMBLY

M18LNO x LW075A

M18LT0 x LW075A

2 24A581 PANEL, air controls, pump and gun

(includes 3b, 42, and 43; see page 31)

1

1

3a 24A576 DATATRAK, assembly, see manual 313541 1

3b ----INSERT, panel (included with Part 2) 1

16 ----2

32 -----

NUT, lock, M5 x 0.08 (included with Part

49)

COVER, gauge, not shown, 12 per sheet

(see page 31 for package of 5 sheets)

1

48 238909

51 -----

GROUND WIRE, pump


SCREW, hex head, M8 x 16 mm (included with Part 49)

54

24A578 WALL MOUNTING KIT, see page 30

1

1

2

1

60 24A590 BRACKET, heated, kit, includes 64, 65, and 66)

1

61 245848 HEATER, fluid, 120V, see manual 309524 1


1/4-20 x 1.25 in. (31 mm)

2

Ref.


63 100527 WASHER, 1/4 in.

64 ----SCREW, M8 x 25

65 -----

66 -----

NUT

SCREW, M8 x 1.25





1/4 in. (6 mm) ID; 1/4 npsm(f)

72 166866 ELBOW, 1/4 npt (m x f), sst


75 24C406 HOSE, fluid, nylon, sst fittings;

1/2 in (13 mm) ID, 1/2-14 nps(m),

3 ft (0.9 m) long


77 112494 ADAPTER, 3/8-18 nps(m) x 1/4-18 npt

81 114874 UNION, swivel, heater inlet, 90°, sst,

1/2-14 nps(m) x 1/2-14 npt


84 222200 VALVE, back pressure, sst;

see manual 307892

85 16A619 SPACER

86 114593 KNOB



2

1

Qty.

1

1

4

1

4

4

2

8

1

1

2

1

1

1

1

1

313255N 29

Kits

Kits

Wall Mount Kit 24A578

ti12633a

Heated Cart Mount Kit 256427

Ref

No.

Description

101 WALL PLATE, kit, includes screws

102 SCREW (included with 101)

Qty.

1

4

102

101

NOTE: Air Controls Mounting Kit 24E883 (Part 49, see

page 27, 28, or 29) also is required for wall mounting a

package that has a control panel.

210

209

215

208

205

202

212

207

201

Ref


201 ----CART, frame

202 ----HANDLE, cart

203 119451 WHEEL, semi-pneumatic

204 119452 CAP, hub

205 ----SLEEVE, cart handle

206 15C871 CAP, leg

207 115480 KNOB, t-handle

208 116630 SCREW, carriage

209 ----BRACKET, heater, cart

210 111799 SCREW, cap, hex head

211 104541 NUT, lock

212 115643 SCREW, hex, washer head

213 100022 SCREW, cap, hex head

214 100527 WASHER, plain


Qty.

2

4

8

2

4

4

2

1

2

2

2

1

1

1

2


203

204

30

211 213 214

206 ti13357a

313255N

Kits

Pump and Gun Control Panel Kit

304 327 307 308

308

307

306

305

311

304

303

302

Kit 24A581

310

313

310

316

328

309

315

312

301 ti13565b

314

317

303

319 ti13467a

321

2

1

1

1

1

1

1

2

1

1

1

2

1

2

1

313255N 31

Kits

Pump Only Control Panel Kit

307 308 304

327

310

313

Kit 24A583

306

305

304

311

303

326

301

317

314 ti13567b

1

1

2

1

1

1

1

1

32 313255N

Kits

DataTrak

NOTE: See DataTrak manual, 313541, for all DataTrak related part numbers and kit information, including the reed switch and solenoid.

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 straight swivel

Wall

24B425 1 in. hose, PTFE lined, with straight Wall swivel

313255N 33

Wall Bracket Mounting Dimensions

Wall Bracket Mounting Dimensions

11 in.

(279 mm)

Four 0.40 in. (10 mm) mounting holes ti12833a

4 in.

(102 mm)

34 313255N

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)

Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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)

Sound data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Technical Data in air motor manual 312796.

Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement pump: Stainless steel, tungsten 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

Technical Data

313255N 35

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 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, 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 rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco 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

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

Revision N, July 2014

Graco 313255N, Merkur Heated Spray Packages Instructions

Instructions-Parts

Merkur

®

Heated

Spray Packages

313255N

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

Contents

Related Manuals

Warnings

WARNING

WARNING

Models

G

28

30

48

C

W

Merkur 28:1 Heated Packages

(G28Wxx and G28Cxx)

Merkur 30:1 Heated Packages

(G30Wxx and G30Cxx)

Merkur 48:1 Heated Packages

(G48Wxx)

Installation

General Information

Wall Mount Packages

Prepare the Operator

Ventilate the Spray Booth

Prepare the Site

Supplied Components

Grounding

Setup

Electrical Housing Access

Hose Connections

Operation

Pressure Relief Procedure Flush Before Using Equipment

Trigger Lock

Wet Cup

Install the Spray Tip

Prime the Pump

Adjust the Atomization Adjust the Spray Pattern

Packages with Airless Guns

Packages with AA Guns

Shutdown

Maintenance

Preventive Maintenance

Schedule

Tighten Threaded Connections

Flush the Pump

Wet Cup

Troubleshooting

DataTrak Controls and Indicators

DataTrak Operation

Setup Mode

Run Mode

Runaway

Prime/Flush

Counter/Totalizer

Display

Diagnostics

Replace DataTrak Battery or Fuse

Replace Battery

Replace Fuse

Parts

G28xxx Models

G30xxx Models

G48Wxx Models

Kits

Wall Mount Kit 24A578

Heated Cart Mount Kit 256427

Pump and Gun Control Panel Kit

Kit 24A581

Pump Only Control Panel Kit

Kit 24A583

DataTrak

PTFE Suction Hose Kits

Wall Bracket Mounting Dimensions