Graco 015.050-DP Operation manual

USER INFORMATION 6000305E

KEEP FOR FUTURE USE Rev. B

B.6.20.44

015.050-DP

020.035-DP

025.008-DP

030.020-DP

030.050-DP

040.035-DP

060.020-DP

Reciprocating pumps MERKUR 2000

*5$&2

GRACO N.V.

Industrieterrein “Oude Bunders”

Loc. 2206 - Slakweidestraat 31

3630 Maasmechelen - Belgium

Tel.: 32 89 770 700 Fax: 32 89 770 777

REGULAR TESTING OF THE APPLIANCES

Person responsible

Test certificate No. Test date Company Name

Liquid spray equipment is intended in particular for surfacing (e.g. airless paint spraying equipment,

two-component coating equipment).

The operator must ensure that liquid spray equipment is tested for proper operation after an

operating pause of more than 6 months, but at least every 12 months by a competent person1).

The operator must ensure that the test results are properly recorded in writing for every liquid spray

equipment2) and kept until the next test.

The operator must ensure that the test certificate is available at the place of use 3) of the liquid spray

equipment.

 A competent person is somebody who on the basis of their professional training and

experience has sufficient knowledge in the field of liquid spray equipment and is sufficiently

conversant with the relevant national health and safety regulations, accident prevention

regulations, recommendations and generally accepted rules and industrial norms that they are

in the position to evaluate liquid spray equipment.

 Written records (test results) can, for example, be in the form of test certificates.

 At the place of use, a copy of the test certificate or a test stamp on the appliance is considered

as compliance with the requirement.

-Extract from: Working with liquid spraying equipment (VBG 87)

Issued on: 10th October 1993

§ 23 (1), (3) and (4)

Implementation instructions VBG 87

to § 1 Para. 1 and to §23 Para. 1, Para. 3, Para. 4

Page 1 of 33

10.99

RECIPROCATING PUMPS MERKUR 2000

USER INFORMATION

- OPERATING INSTRUCTIONS - Issued

B.6.20.44-B

Subject to change

Note the protection mark in accordance with DIN 34

Approved 19.10.99 Kuhn

Proc. 15.10.99 Hilse

F22.060.01, issued on 01.98

*5$&2

The original manufacturer’s designation can be found on the

reciprocating pump.

Please compare all specifications and complete, if necessary.

All important sections in this Operator Manual have been marked

with the following symbols:

Directions involving your safety

Important operational directions

Ensure that all other users know and understand all safety directions.

CONTENTS OF USER INFORMATION

Page

OPERATING INSTRUCTIONS

CORRECT USE 2

FUNCTIONAL DIAGRAM 3

DESCRIPTION OF FUNCTIONS 4

EQUIPMENT COMPONENTS – IMPORTANT INFORMATION 4

LIST OF TOOLS 15

INSTALLATION 15

START UP 19

IMPORTANT INFORMATION REGARDING START UP AND OPERATION 21

OPERATION 22

MAINTENANCE AND INSPECTION, REPAIRS 22

THREADED CONNECTIONS 27

SHUTTING DOWN 29

SOLVING BREAKDOWNS 29

NOTES 32

Pulsation reducing measures 32

Self-check 33

Guidelines, directives and regulations 33

User information 33

Read and understand the operator manual and the safety

instructions before taking the pump into operation

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- 2 - B.6.20.44-B

F22.060.02, issued on 01.98

CONTENTS – CONT’D

Page

TECHNICAL DESCRIPTION OF PRODUCT

DESCRIPTION OF THE RECIPROCATING PUMP 01

SUITABILITY, MATERIAL 02

TECHNICAL DATA 03

Key to designation, the module 03

DATA 04

Sound emission 05

Construction materials of wetted parts 05

Dimensions, connection threads, nominal diameters, attachment position 06

LIST OF REPAIR PARTS

REPAIR – RECIPROCATING PUMPS, REPAIR – ACCESSORIES (Sales catalogue extract)

Includes:

TEST CERTIFICATE (final inspection)

EC DECLARATION OF CONFORMITY

BRIEF USER INSTRUCTIONS (can be adhered to pump)

BRIEF OPERATING INSTRUCTIONS, WARNING SIGNS

CORRECT USE

The MERKUR 2000 reciprocating pumps are exclusively manufactured for the usual applications in

surfacing technology (to convey coatings or auxiliary agents or for spraying) or similar work.

Any other purpose above and beyond this is considered inappropriate use. We shall not be liable for

any damage or injury resulting from this; the user shall bear sole responsibility in such cases.

Correct use includes observing the operating, maintenance and inspection conditions and

regulations laid down by us.

The MERKUR 2000 reciprocating pumps should only be operated, maintained and serviced by

personnel familiar with, and trained to recognise its inherent dangers.

The relevant accident prevention regulations as well as safety and medical rules must be observed.

In case of unauthorised modifications of the appliance we cannot be held responsible for any

damages or injury resulting from such modifications.

The user is responsible for the correct installation of the equipment.

3 - B.6.20.44-B

F22.060.03, issued on 01.98

FUNCTIONAL DIAGRAM

RECIPROCATING PUMP 1Air pressure container 9Fluid container

AIR PRESSURE SUPPLY 2Pipeline or hose bl Suction line

(Suction tube)

EXHAUST AIR SOUND

SUPPRESSION 3Pressure control valve bm High-pressure

screen

FLUID SUCTION SYSTEM 4Ball valve bn Pressure line

FLUID PRESSURE SYSTEM 5Ball valve bo Spray gun

APPLIANCE SUPPORT 6Safety valve bp Screen

7Safety valve bq Liquid model

8Sound absorber br Filter regulator

Compressor

- 4 - B.6.20.44-B

F22.060.02, issued on 01.98

DESCRIPTION OF FUNCTIONS

The air pressure is supplied to the reciprocating pump from the pressure tank 1via a tube or

hose line 2and a pressure control valve 3.

The air supply from the pressure tank to the reciprocating pump can be interrupted by the ball valve

The ball valve 5is used for manually releasing condensation (an automatic steam trap would be

preferable here).

The safety valve 6protects the pressure tank against inadmissible rises in air pressure (e.g. in the

event of heating).

Since as a rule the air pressure supply is not installed for the reciprocating pump and because it

is obligatory, the reciprocating pump is also provided with a safety valve 7.

During operation of the drive (air motor) of the reciprocating pump, the air pressure escapes into the

atmosphere via the silencer 8.This releases its pressure.

The fluid (coating or auxiliary agent) is sucked into the reciprocating pump from a container 9via

the suction line bl and supplied under pressure to the spray gun bo via the high-pressure screen

bm and pressure line (hose or pipe) bn.

A sieve (dirt trap) bp protects the reciprocating pump against foreign bodies which have accidentally

entered the fluid.

A liquid unit (detergent unit) bq is essential in reciprocating pumps of this design. The operating

position (attachment position) of the reciprocating pump will depend on it.

Since the appliances also use AIRLESS PLUS for spraying (air-boosted high-pressure spraying

equipment), it is recommended to attach a filter regulator br at the air pressure branch.

EQUIPMENT COMPONENTS – IMPORTANT INFORMATION

The following components are required in an operational system:

THE RECIPROCATING PUMP

Functional description of the reciprocating pump; following part "Technical Description of

Product B.6.20.44-P".

AIR PRESSURE SUPPLY

The air pressure supply consists of the compressor, the pressure tank with steam trap,

possibly an air pressure drier and pipeline.

The air pressure supply is generally already available to the user.

- When air pressure supply needs to be installed, the relevant accident prevention

regulations, safety rules and user information must be observed, in particular the

information supplied by the manufacturer of the compressor.

5 - B.6.20.44-B

F22.060.03, issued on 01.98

There must be a flexible connection between the reciprocating pump and the air pressure line

(avoids fractures caused by vibrations). A hose line is most suitable

- Nominal diameter 9 or larger

- Operational pressure = max. mains pressure, preferably ( 16 bar

- air and ambient temperatures -20° to +50 °C

- free from any substances that may interfere with paint spraying, such as silicone

In areas with a danger of explosion the air pressure line and the hose line must be electrically

conductive (to avoid electrostatic charging).

-Discharge resistance < 106Ωrelative to earth.

The pressure control valve is in most cases directly fitted to the reciprocating pump.

- Efficient flow rate

at 6 bar and 25m/s > 50 m3/h

- Air inlet pressure 16 bar

- Air and ambient temperatures 0° C to 50° C

It goes without saying that the pressure control valve can be situated between the hose line

and the air pressure line.

The manometer – 3.1 in functional diagram – enables accurate adjustment and monitoring of

the necessary air pressure.

- Display range 0 to 16 bar

- Air and ambient temperatures 0° to 50 °C

- Damped construction

A shut-off mechanism (e.g. a ball retaining valve) should always be fitted between the

pressure control valve and the hose line, or between the hose line and the air pressure line.

This enables quick and safe switch-off of the reciprocating pump for operational breaks,

maintenance work and in cases of breakdown.

- Do not change the values set on the pressure control valve

- Rated pressure ≥15 bar

- Material CuZn, nickel-plated

The rule for ball retaining valves: wings transverse to flow direction = line is closed off

Do not use PTFE tape or hemp to seal connections

(- malfunctioning of pressure control valve - as a result of residue in air pressure supply).

- 6 - B.6.20.44-B

F22.060.02, issued on 01.98

There are no special requirements as regards the quality of the air pressure supplied to the

reciprocating pump.

- Condensation and residue oil from the compressor are trapped

(pressure tank, air filter)

- Lubrication of compressed air not necessary

- Temperature of compressed air 10° C to 50° C

When compressed air is used for fluid atomising, a filter regulator, branched off from the main

compressed air supply – 16 in functional diagram – must be installed upstream.

- Efficient flow rate

at 6 bar and 25m/s > 32 m3/h

- Air inlet pressure 16 bar

- Air and ambient temperatures 0° to 50°C

EXHAUST AIR SILENCER

Without a silencer the sound emission of a reciprocating pump operated by air pressure is

high [ > 100 dB(A) ] and causes damage to hearing. Since there is a relationship between

sound absorption and icing of the reciprocating pump control system, it is not possible to lower

the sound pressure level as much as desired (not 70 dB(A)].

All MERKUR 2000 reciprocating pumps are therefore equipped with appropriately

dimensioned silencers.

The reciprocating pumps may not be operated without the silencer.

The silencer must not be screwed off during operation.

- The decision to wear ear protection depends on the operating pressure and the

resulting sound level.

The air pressure must be free from any substances that may interfere with

paint spraying, like silicone or oil.

- This also applies to component parts of the air pressure supply.

See "Technical Description of Product B.6.20.44-P", page 05

for more detailed information on the sound level.

7 - B.6.20.44-B

F22.060.03, issued on 01.98

FLUID SUCTION SYSTEM

The suction connection of MERKUR 2000 reciprocating pumps is constructed in such a way

that both a swivel unit (angular or T-shaped) and a connector or suction pipe can be screwed

in.

The connection units 1and 2are used for connecting the suction system, the suction line

and the suction cup. The connector 3is only used for retrofitting. The end of the thread is 4

situated at the suction pipes.

Most of the reciprocating pumps are equipped with the

connection unit 1and a suction system (suction hose,

tube and suction sieve).

The swivel connector enhances the flexibility of the

suction hose so an almost empty fluid container will not

be turned over by the recoil force of the suction hose.

The diameter of the suction line is dimensioned in such a way that fluids with a kinematic

viscosity of up to 750 mm2/s (cSt) can be sucked without difficulty by the reciprocating pump.

A higher viscosity rating can result in a reduction of suction performance, or even result in

interrupted suction, which can be identified by an increasing pressure drop during the change

of direction (pulsating pressure).

- Measures for improvement are:

keeping the suction line as short as possible or a short suction hose with a larger cross

diameter.

Specifications of suction assembly:

Electrically conductive, maximum permissible resistance 3 x 104Ω/m (tested to ISO 8031)

and leakage resistance to earth < 106Ω.

(Suitable for use in hazardous locations.)

Suction

Connector 1

- 8 - B.6.20.44-B

F22.060.02, issued on 01.98

The individual parts of the suction system are designed to withstand an excess pressure of

12 bar (- Suitable for suction heights of up to 8.5 m).

The suction hose and the suction sieve are resistant to the usual solvents in the surface

coating and are silicone-free.

Minimum rated diameter 19

Fluid temperature 10 °C to 85 °C

Mesh size of screen 1.8

In case of a fixed installation the connection between

reciprocating pump and fluid container must be flexible

(to avoid rupture caused by vibration).

The ratings for this connecting suction line must

correspond with those of the suction equipment.

The admission pressure (pressure in a supply system, e.g. in a circuit) acting on the

reciprocating pump and the suction line, must not exceed 10 bar.

When a threaded tube is used in the suction assembly, the manufacturer’s directions for

installation of the screwed connection apply.

The viscosity of thixotropic fluids is reduced by stirring;

this improves e.g. the suction behaviour of the

reciprocating pump.

The agitator is clamped to the suction equipment. The

clamp (holder) must be fastened to the rim of the fluid

container. This ensures correct positioning of the

propeller of the agitator relative to the wall and base of

the container as well as to the suction tube, and prevents

the parts from touching.

All metal parts in contact with the suction area material are made of austenitic

stainless steel. (suitable for use with water lacquer).

All immersed parts of the agitator (spindle and propeller) are made from austenitic

stainless steel (suitable for water-based paints).

Connector 1

Suction pipe

Suction

Agitator

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