Instructions/Parts Merkur™ Bellows AA and Airless Spray Packages 312799L EN Spray packages with a bellows seal for use with isocyanates, UV coatings and other moisture-sensitive materials. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See pages 9-14 for model information, including maximum air inlet pressures and maximum fluid working pressures.
Contents Contents Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Important Two-Component Material Information . 7 Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7 Keep Components A and B Separate . . . . . . . . .
Related Manuals Related Manuals Manual Description 312793 Merkur Bellows Displacement Pump 312795 Merkur Bellows Pump Assembly 312796 NXT™ Air Motor 312798 Merkur Electrostatic Packages 3A0149 G15/G40 Spray Gun 312145 XTR™5 and XTR™7 Airless Spray Gun 307273 Fluid Outlet Filter 312799L 3
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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.
Warnings WARNING WARNING 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 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.
Warnings WARNING WARNING 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 MSDSs 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 chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocyanates 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 ventilation in the work area.
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 G15B54 represents a Merkur package (G), with a 15:1 ratio pump (15), bellows style (B), and the components shown for (54) in the table on page 10.
Models 5:1 Packages (G05Bxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 500 psi (3.
Models 15:1 Packages (G15Bxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 1500 psi (10.
Models 23:1 Packages (G23Bxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 2300 psi (15.
Models 24:1 Packages (G24Bxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 2400 psi (16.
Models 25:1 Packages (G25Bxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 2500 psi (17.
Models 35:1 Packages (G35Bxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 3500 psi (24.
Installation 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 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 and FIG. 2 are only guides for selecting and installing system components and accessories.
Installation Prepare the Site Keep the site clear of any obstacles or debris that could interfere with the operator's movement. Ensure that you have an adequate compressed air supply. Have a grounded, metal pail available for use when flushing the system. Bring a compressed air supply line from the air compressor to the pump location. 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.
Installation Mount the Pump • Mount the pump directly to the wall (order Wall Mounting Kit, page 39) or to a Graco cart (order Cart Mounting Kit 24E879). The pump air regulator (H) 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. Wall-Mounted Pumps • The gun air regulator (D) adjusts the air pressure to the air-assisted spray gun (L).
Installation Air Line Accessories Fluid supply container: follow local code. Install the following accessories in the order shown in FIG. 1 and FIG. 2, using adapters as necessary. Object being sprayed: follow local code. • An air-line filter (B) removes harmful dirt and moisture from the compressed air supply. • A second bleed-type air shutoff valve (A) isolates the air line accessories for servicing. Locate upstream from all other air line accessories.
Operation Operation Pressure Relief Procedure Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts. Flush the Pump Before First Use The pump is tested with lightweight oil, which is left in to protect the pump parts. If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent. See Flushing, page 22. Trigger Lock 1. Lock the gun trigger. 2. See FIG. 2. Turn off the bleed-type master air valve (E).
Operation Prime and Adjust the Pump NOTICE TO PREVENT A BELLOWS FAILURE: • Do not exceed fluid inlet pressure of 15 psi (0.1 MPa, 1.0 bar). • Do not use a ball check pump on the inlet side of this pump. • Do not use a suction tube with a check valve on the inlet side of this pump. 1. Lock the gun trigger. Remove tip guard and spray tip from gun. Refer to gun manual. 2. Close gun air regulator (D) and pump air regulator (H) by turning knobs counterclockwise reducing pressure to zero.
Operation Adjust the Spray Pattern W W OUT (narrower pattern) IN (wider 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.
Maintenance Shutdown Follow Pressure Relief Procedure, page 19. Flushing Read all Warnings. Follow all Grounding instructions. See page 18. Flush the pump: Always flush the pump before the fluid dries on the displacement rod. See Flushing on page 22. NOTE: If the overflow chamber (optional accessory) contains fluid, unscrew the bottle (103) and discard. If it has not been used, the bottle can remain attached to the cap.
DataTrak Controls and Indicators DataTrak Controls and Indicators Key for FIG. 8 AA Runaway Limit, in cycles per minute (user settable; 00=OFF) AB Lower Displacement (user settable) AC Flow Rate Units (user settable to CF BT GT RT UT DT ST /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.
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. Setup Mode 1. See FIG. 8. Press and hold Setup menu appears. 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. for 5 seconds until 2.
DataTrak Operation Prime/Flush Display 1. See FIG. 8. To enter Prime/Flush mode, press any See FIG. 8. The display (AE) will turn off after 1 minute of inactivity in Run mode or 3 minutes in Setup mode. Press any key to wake up the display. 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.
DataTrak Operation Table 1: Diagnostic Codes Symbol Code Code Name Diagnosis Cause Runaway Pump running faster than set runaway limit. • Increased air pressure. • Increased fluid output. • Exhausted fluid supply. E-1 Diving Up Leak during upstroke. Worn piston valve or packings. E-2 Diving Down Leak during downstroke. Worn intake valve. E-3 Low Battery Battery voltage too low to stop runaway. Low battery. Replace battery; see page 27.
DataTrak Operation Replace DataTrak Battery or Fuse 5. Disconnect the used battery and replace with an approved battery. See Table 2. 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 TABLE 2, and an approved fuse, shown in TABLE 3. Use of an unapproved battery or fuse will void Graco’s warranty and Intertek and Ex approvals. Table 2.
DataTrak Operation Replace Fuse Table 3. Approved Fuses DataTrak Part Number 1. Remove the screw, metal strap, and plastic holder. 2. Pull the fuse away from the board. 289822 3. Replace with an approved fuse from Table 3. All other part numbers Series* Fuse Required A or B C and later A B and later 24C580 24V216 24C580 24V216 * Fig. 12 shows where to find the Series letter. Solenoid Cable Connec- Fuse Sensor Cable Connection Series Letter (last digit of code) Battery ti11994b FIG. 12.
Troubleshooting Troubleshooting NOTE: Check all possible problems and causes before disassembling the pump. Follow Pressure Relief Procedure, page 19, 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. Cause Restricted line or inadequate air sup- Clear line or increase air supply. Check ply; closed or clogged valves. that the valves are open.
Parts Parts Cart Mount 3a 3b 2 16 15 56 32 55 57 18 58 29 17 1 17 7 13 6 30 4 60 43 46 44 45 5 ti15429a 30 312799L
Parts Wall Mount 15 29 1 3a 18 3b 16 32 17 46 28 2 17 30 43 4 6 7 13 44 45 5 ti15430b NOTE: • • See page 39 for mounting kits for all packages. See pages 38-44 for repair parts and accessories.
Parts G05Bxx Models G12Bxx Models This list includes all possible parts for G05Bxx packages. See page 9 to check whether a part is included in your particular package. This list includes all possible parts for G12Bxx packages. See page 9 to check whether a part is included in your particular package.
Parts G15Bxx Models This list includes all possible parts for G15Bxx packages. See page 10 to check whether a part is included in your particular package.
Parts G23Bxx Models This list includes all possible parts for G23Bxx packages. See page 11 to check whether a part is included in your particular package.
Parts G24Bxx Models This list includes all possible parts for G24Bxx packages. See page 12 to check whether a part is included in your particular package.
Parts G25Bxx Models This list includes all possible parts for G25Bxx packages. See page 13 to check whether a part is included in your particular package.
Parts G35Bxx Models This list includes all possible parts for G35Bxx packages. See page 14 to check whether a part is included in your particular package.
Kits Kits Cart Mounting Kit Kit 24E879 Includes the cart, mounting plate (30), and hardware for all pump sizes. Use to mount a bare pump on a cart. See details in kit parts list to determine the hardware needed for your pump. 102 18 15 16 1 Ref.
Kits Wall Mounting Kit Air Control Mounting Kit-Wall Includes mounting plate (30) and hardware (see Mounting Hardware Kits). Use to mount a bare pump on the wall. Kit 24E883 includes bracket (28), hex nuts (32), and screws (17). Use if adding air controls to a wall mount package, or for replacement parts.
Kits Pump and Gun Control Panel Kits 310 304 327 307 308 313 319 310 308 316 307 303 314 306 317 305 328 311 309 315 312 304 303 301 302 321 ti13565b M07xxx, M12xxx, and M18xxx air motors M04xxx air motors Kits 24A581 Kit 24A585 Ref.
Kits Pump Only Control Panel Kits 307 308 304 327 310 310 307 327 313 313 308 306 305 304 ti13567b 306 305 303 326 304 311 ti13566b 301 317 314 311 303 326 325 324 301 317 314 M07xxx, M12xxx, and M18xxx air motors M04xxx air motors Kit 24A583 Kit 24A586 Ref. Part Description Qty. 301 114362 VALVE, ball 1 303 ----- TUBE, 1/2 OD, cut to fit, 1.5 ft.
Kits DataTrak Kits DataTrak Conversion Kits 401 Part Description 24A575 DataTrak with Runaway Protection Kit Fits NXT Air Valve Air Motor Replacement Kit Models Required* M04LN0 24A353 M04LT0 ----- M07LN0– DataTrak with M18LN0 24A576 Runaway Protection Kit M07LT0– M18LT0 DataTrak with 24A592 Cycle Count Only Kit 402 MxxLN0 24A354 --------- * Purchase and install the Air Valve Replacement Kit listed to make your MxxLN0 air motor compatible with DataTrak with Runaway Protection.
Kits Drain Valve Kit 256425 Includes drain valve (43), coupling (44), and hose (45). Overflow Chamber Kit 24E298 Includes overflow cup, with seals and necessary hardware. Reinforced PTFE V-Packing Kits and PTFE Bellows Kits NOTE: See manual 312793 for information related to optional kits with reinforced PTFE seals and optional kits with PTFE bellows. These kits are intended for use with materials that cause chemical compatibility concerns with UHMWPE, such as acid catalyst materials.
Kits Guns and Hoses G15 and G40 To find the correct parts for your model, locate the gun you have. The correct hoses and related parts are listed in the table below each gun. 10 8 14 XTR 5 22 42 10 40 9 9 ti11993a Ref. Part ti12636a Ref. Part 9 10 40 42 44 Description HOSE, fluid 241812 G05xxx-G24xxx, 25 ft (7.6 m), 3300 psi (22.7 MPa, 227 bar) maximum working pressure 24A446 G35xxx, 23 ft (7 m), 4100 psi (28.
Mounting Plate Dimensions Mounting Plate Dimensions 6.9 in. (175 mm) 2.167 in. (55 mm) 8.5 in. (216 mm) 17.0 in. (432 mm) 6 x 0.400 in.
Mounting Plate Dimensions 46 312799L
Technical Data Technical Data Maximum fluid working pressure . . . . . . . . . . . . . See Models tables on pages 9-13. Maximum fluid inlet pressure . . . . . . . . . . . . . . . . 15 psi (0.1 MPa, 1.0 bar) Maximum pump air inlet pressure. . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar) Minimum air inlet pressure . . . . . . . . . . . . . . . . . . 10 psi (0.07 MPa, 0.7 bar) Maximum gun air inlet pressure . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar) Ratio . . . . . . . . . . . . . . . . . . .
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.
